Good thread! About time we talked about real world performance instead of just peak numbers. Jerry said it very well, above. I'm no expert but here is a recent experience:
I originally went with a HD heavy breather, Dynalink ecm upgrade and tune, drilled cat and 2" fullsac muff cores. After lots of reading and discussion with Steve at Fullsac, I went with the Andrews 54 CAM and swapped out to a Cat-less header pipe. Steve also recommended a thinner head gasket which I had installed for a (very) slight increase in compression. After re-tune, the bike "mapped" at 106 HP and 116 ft lbs. Best, it's a very flat torque curve with over 105 ft lbs between 2,400 and 5,200 rpms and the 110 peak at 3,700. Does not sound like I'm going to keep up with some of the bikes described above but....
This month, I rode from Los Angeles to Lake Havasu with three other bikes mostly cruising at about 75 mph, also went through Kingman AZ, Boulder City and Laughlin, NV. For the trip, I averaged about 47 mpg.
The other bikes (all with batwing fairings and lowers) were:
1. 2008 SEUC with ventilator a/c from my SERG, fullsac 2" cores, no cat and power commander,
2. 2010 Ultra LTD, with power commander and V&H Power duals and
3. 2006 or 7 Ultra with a 96" (five gallon tank) with power commander high flow and Rinehart true duals
At each gas stop, about 165 miles, I would need about 3.5 gallons; the '08 about 4, the '10 about 4.2 and the Ultra 4.5-4.7. We were all impressed by the more than a 10 mpg difference. We did not race but the SERG certainly pulled harder up highway on ramps. Have to think my set up was more efficient but also the SERG fairing is more aerodynamic. I was the only one without lower fairings. We all had tour paks. Ride on.
GK