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In the short time I've been doing this, I've found the biggest (cheap or free) improvements from what I've tried so far to be:
1) a grille block
2) increasing the air in my tires
Each of these things raised my mileage by approxiamtely 1.5 miles per gallon in conscientious testing. Now, my first grille block, made out of cardboard and attached to the OUTSIDE of the car with duct tape probably qualifies for the "makes my car look like a joke" status. However, because the cardboard got wet in the rain and fell apart, I'm doing a second one out of clear plexiglass taped on. Though still somewhat "obvious", it is far less - "redneck" - looking than the cardboard. I believe others on here have done INTERNAL grille blocks (behind the grille) that are practically invisible, but I have no experience with that, or the results.
The over-inflated tires are, of course, "invisible" to anyone looking for ugly ecomodder looking stuff, too.
If your car has a roof rack you seldom or never use, I found that removing mine gave a small improvement (just under 1/2 MPG), and I like the "cleaner" look without it, anyway. And it didn't cost anything to do that, either.
So that's what I have for you.
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