slowmover, just a few comments on what you said.
1) On the fan, you're probably correct. My thinking is a CLUTCHED mechanical fan is probably superior to an electrical fan from an efficiency perspective because there aren't the conversion losses ( I can see where an electric fan would have an advantage over a non-clutched mechanical fan). Also, unless you're doing a lot of driving where you're really working the engine at low vehicle speed, I don't think you're clutched fan is going to run that much anyway.
2) Your note on careful record keeping is right on. If you're not doing that you're just fooling around.
3) I totally agree with your point that you have to think about all mods from a TOTAL cost perspective, rather than only a FE perspective. If you spend $1,000 on something that improves your FE by 0.1% on a pickup you're crazy.
4) Regarding the "aftermarket gizmos", I have to disagree somewhat with what you said. You really have to look at things on a "gizmo by gizmo" basis. You are correct that some mods are going to result in premature failure, so don't do those. However, some mods will actually increase your mechanical life IF done correctly (removing EGR for example). The key is to be patient and really understand what you're doing BEFORE you do it. Know what to do. Know how to do it. Know why to do it. You should research the whazoo out of a mod before you go out and do it.
5) Maybe I misunderstood you, but you seem to have the idea that, "If it led to better FE and/or better engine life, then the manufacturer would have done it so don't mess with anything." This I have to disagree with. The one thing that you're forgetting about is emissions regs. Engine manufactures have been forced to add components and calibrations that significantly hurt initial cost, engine wear, and fuel economy. Case in point are the DPF's (diesel particulate filter). They add a bunch of initial cost, a bunch of maitenence cost, burn a bunch of fuel (both in regens and added backpressure), and they prevent the driver from driving effectively for FE because you need to keep your exhaust temps up.
All that being said, I geneally like the way you think!
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