Blacksheep, Sorry, I missed this question till now. .
Yes, have tried several different approaches from can bus/timing boxes, to programmers, tap wire boxes, air boxes/filters, tire tread types, exhaust setups, & several different sets of injectors. Didn't see a whole lot of difference in fuel mileage with any of the different combos (maybe 2 mpg's average between the different combos overall). Probably one of the biggest things I particularly noticed is with the timing increase, the eqt's drop significantly, and possibly a touch better mpg's but more engine rattle and probably higher cyl pressures while towing heavy.
Decided that the real number one goal is reliability/simplicity, 2 is drivability, 3 is being able to pass a smog inspection via keeping things appearing and sounding as stock as possible, 4 is mileage (something like that anyways - forgot the other one).
With those priorities in mind, got rid of all the added electronic power boxes (except for a practical solutions boost module that is tucked away and blended into the stock wiring as best as possible), and went back to the stock airbox, but added the extra black intake tube to the cowl so its pulling only outside air. Also went quiet on the exhaust, and even put the turbo silencer ring back in.
Just running the injectors for more power and have to say, drivability is very good, the VP is running at close to stock specs, and the motor isn't rattling much at all for a 2nd gen, so this has turned out to be a pretty decent combo.
Did try the RV275's with a smarty on #1 and as you say, that combo did give some of the better mileage numbers this truck has seen, along with low smoke, less touchy throttle, and low egt's also. The downsides were quite a bit of timing rattle, and I can only imagine that there would be some pretty high cylinder pressures while pulling heavy, but they warn you about that in the instructions so you just change programs for towing.
Yeah, I agree with you that genuine 275's were very nice injectors overall. These Mach 2's are pretty darn clean for their power gain also. Was impressed. .
That was the long answer. .
But in staying with subject of the thread, the connector tubes on this truck have been re-used probably 6 or 7 times and still seem to be ok.