twiget
1/2 ton status
I don't think you'll get anywhere NEAR 20MPG. I hate to be negative, without going hybrid or diesel, it ain't happening. If it was possible, GM would have done it.
I think GM could have gotten better MPG out of big trucks. The down side would have been that the trucks would have cost a lot more.
The best things you could do for mileage on a burb are:
-get an overdrive transmission with lockup torque converter (or manual with overdrive gearing)
-get tall skinny tires
-get tall (numerically low) gears
-keep your truck stock height or even lower it
-get a 2WD
-get a diesel
I've looked into swapping in a 4L85E. Other than the serious $$$ for the tranny itself, there would be a fair amount of work involved. The tranny is a different length than the TH400, so that means a resized drive shaft, and probably relocating the tranny cross member.
I already swapped out the 4.10's, and put in a set of 3.42's. That got me an extra 3mpg alone.
I have considered taller tires, and lowering the truck, but they are kind of mutually exclusive. I think I'll probably lower it an inch or two, and keep the stock size tires.
I think the weights savings with aluminum heads on a truck is a moot point, It's not going to help much to save 40 pounds when you weight 5500.
I think what would be ideal is saving for a ls1
I am definately contemplating an LS series motor. They are expensive though, so that is probably a few years down the road. I wonder how well a super charged LSA would work in a tow rig?

Seriously though, Some engine mods are next, thus the question about iron vs. aluminum.