I'm a regular hypermiler; read the ecomodder website thoroughly.
Things i have done so far:
Antenna tucked, stock size tires at 40lbs (44lb max), side mirrors folded in, 5spd short shifting, EOC as much as possible, nothing sticking out on the outside to create drag, car is always empty of stuff, 55-60 max mph during mpg testing, etc.
Soobiedoo you said the AC fan is already set up to come on via thermostat? I thought it ran on a switch when the AC was turned on? The fan blades are different between the belt and the electric fan as well.