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Would anyone like to guess as to how much the CA Smog system effects my mileage? I live in Oregon now and there are no smog checks and no special emissions requirements. Just wondering if it'd be worth the cost to have it removed. With the cost of Diesel not going down like gas is, perhaps it's time to consider a change.
Anyone?
The only operational difference with Fed smog on your 2007 is programming. The remainder is minor electrical (which doesn't affect performance or economy). You can try a reprogram, or another PCM, but other than what that calibration has been modified to do, your CA smog truck won't behave any different than a Fed smog truck.
Since the 2004.5 M/Y, the only significant differences between CA and Fed smog Duramax trucks is the calibration programming. 2001 CA trucks were the same, except for programming and minor electrical. 2002-2004 LB7's had EGR and Cat, Fed's did not. Since 2004.5, they are all physically identical, except for minor electrical variations.
Just noticed in your sig. you already have a Kennedy tune. I don't think there's anything more you can do to improve your performance and/or economy, unless he has something new.
Larger exhaust is always an improvement, so if you haven't done that, perhaps consider it.
(disclaimer)
There are other ways to improve what you have, but are only advised for off-highway use (as in, not legal).
Even though you have moved to where they don't test, it is still not lawful to modify any emission system, state or federal, no matter where you live, unless it is only modified to meet compliance within the state it's registered, as required by the authority.
The only "smog" that you have is the cat (DOC) and I'd not worry too much about that. My 07 still runs the cat and stock exhaust. I think the Cat helps shift the stink of the exhaust to be a little less "wet and offensive. It used to be with the analog turbos we'd need to free up the exhaust more, but now with the variables it's not so critical.
I might suggest lift pumps and secondary fuel filtration to help with longevity.