More SC comments
Alum vs iron head. Not really a topic for further discussion IMO. Aluminum heads are used on just about every turbo/supercharged production car/truck in the world, save the diesel trucks. Millions of them. Stainless valves, sodium filled valves, special head bolts, metal head gaskets, forged cranks, low CR pistons, hardened bearings, piston oil squirters.... IOW, it's what's attached to the block and head that differentiates a forced induction motor.
Boost vs HP draw on the SC. According to Eaton, expect 6.5psi to draw around 25hp. Expect 8.5psi to draw around 33hp.
On boost vs off boost. The M90 uses an internal bypass valve, so under vacuum it has no load (rephrase, no more than a turbo). My gas mileage on the highway didn't change (running stock tires and suspension, TJM front only) at all. My city milleage changed a lot, but driving it without boost, it's the same.
HG failure. Like hard drives, all headgaskets fail, it's not if, it's when. My investigation of the 1FZFE engine design indicates that water flow at the back of the head isn't optimal. Add in the EGR on top of that, I can see the gasket being stressed. I am not convinced the SC will affect head gasket failure one way or the other. I am the test dummy for the head gasket, as I bolted my SC on at 110k with the stock gasket, and am now at 129k.
Shift vs boost. I agree, long boost hills are best addressed at 3psi with overdrive locked out, than 6.5psi with overdrive in. I found no change in mileage doing in the eastern mountains with a tandem trailer attached a couple weeks ago.
I also found that my original 02 sensors took a dump on that trip, which really affected mileage.
I also found that code 71 (EGR valve) exists on a 94 truck. Changed the vacuum orientation at the Tbody during a idle valve swap the other day, code 71. Not sure how or why, I thought that was a CA thing.
MacGuyver, ck the search engine on the SC and turbo, there is a LOT of information already in the archives.
HTH
ST