So I finished up the first tank running the "tricked Nikki" last night and my MPG's seem to be moving in the right direction now. I got almost 23mpg which is a 3mpg increase since fooling the Nikki carb and a 6mpg increase since discovering the issue. This isn't far off from the truck's personal best of 27mpg (on Summer gas) if you allow for a 10% drop in mileage due to running Winter mix fuel now (which would make the target 24mpg based on Winter blend fuel). It may have actually hit that target but the choke flap hung up in the carb on the way home the other night after working on a friend's Weber and the truck would rev to almost 3k when in neutral and the AFR was pig rich. But it was late and cold so I let it ride and fixed it the next day
Here's the graph so far:
You see the sharp drop off where I discovered the the Nikki had massive vacuum leaks and fixed them. At the trough was were where I assumed the carb was running in limp mode and the leaks were actually helping it. The ups and downs on the graph were the process to alleviate this (without AFR data to rely on). Then the upward climb is after I installed the AFR gauge and started tuning it out. At least it's tracking upward now
My plan is to continue to run the Nikki for 2 more tanks since it's takes at least 3 data points to form an average. I prefer at least 5-6 for better resolution, but in the interest of time I'm going with 3 so I can move ahead with future modifications.
After the Nikki I'm going to install the Holley 5200 and track it for 3 tanks (after tuning for proper AFR) and see if there is further improvement. Also, at some point I want to decrease the rear gear ratio. I noticed last night that my AFR's were dead on (14.2 - 14.5) until I got over 65mph, at which point they would drop like a stone down to 11's to 12's. The engine was turning almost 3k above 65 and the truck was screaming for another gear. I'm hoping to pick up a set of 3.63's and 3.30's this weekend for testing in the truck.
After that it's on to installing DIS on the wore out engine and see if that yields any gains before doing the 2.2 12V swap
I know this will take a while, but I'm a "1 variable at a time" kinda guy since it allows me to collect more accurate data for mods vs. gains/losses.