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Have you considered a Gear Vendors over/under drive? Wouldn't help for towing or off road, but would provide an additional overdrive gear for daily driving. That might get your MPG numbers to where you want them.
Don, I have no doubt it is with your capabilities. Another project, no problem as you KNOW the outcome will really be what you wanted from the start.Not to rub it in, but there are a few hints alone the way urging the dmax all along. Kinda like the rear end which ended up being a nice solid 10.5.No OD needed, just go with the cheapest doner you can get. Even the older 5sp ally has an update to 6sp OD.I think the hardest part will be getting the ally in there, farm out the harness.For what you have done to the current motor, it should fetch some coin.