Hi Myron, used to be a flatbedder so nearly everything you write about sounds familiar. I'm impressed by the 8.5 mpg overall, and I know that tractor is a whole lot better to own/drive than the Freightshakers I had to drive. 3.55's on the rear? I always figured the "perfect" truck was a midroof with good aero, 500HP of Cummins with 13-speed & 3.55's. Sorry I don't know about your specific questions, but hope the rest of this may be of help or at least entertaining.
I'm impressed by the genny/inverter set-up, didn't realize that dash air was such a drag . . frankly, though, I'd keep it over an alternative source 'cause when it's needed it's really needed. So why not curtain off the sleeper entirely (only way to stay cool in Texas some days). A larger evaporator coil on the current system is one approach (with relay-driven fan control), plus a better condensor (not tube & fin) to up efficiency and lengthen compressor cycle time interval. Moving the interior air temp sensor may also be of help.
Don't know how the budget is, but PITTSBURGH POWER is always good for some tips: custom-made low restriction muffler, etc:
W900 Style 5 in 5 out muffler - Pittsburgh Power - High performance diesel engine systems
• View topic - October 2009: The $20,000 muffler!
• View forum - Power and Fuel mileage
Bruce Mallinsons site is worth the time to go through for the tidbits. I'd consider some of the less expensive items short of a power box.
Here's a series on a truck build for economy (notice the excellent record keeping):
Stories
Stories
Stories
Stories
Over on
http://www.bobistheoilguy.com you should search out the posts and excellent informed commentary on big truck operation by DOUG HILARY an Australian fleet owner & international consultant in re fluids, etc. Take your time to go through all his posts on this subject (he also posts on cars); another very bright guy for all other subjects over there is MOLAKULE.
http://www.bobistheoilguy.com/forums...&Number=528355
I have taken my oil analysis business to Terry Dyson of
Dyson ANALYSIS some years back. It's an art, not just a science and he's great to deal with (my personal vehicles).
Finally, a favorite from the RV world:
an airspeed indicator to check "winds aloft". I've re-routed myself more than once with an overdimensional load and ******* head & crosswinds after trip-planning weather study.
http://www.aircraftspruce.com/catalo...nasi160m-3.php
Good luck
.