I would just save the money and put a S/C on that 5.3. The 5.3 is a great motor and you would save a lot of money that way.
I like thisa one :) http://www.kennebell.net/superchargers/gm/gm48-60/gm48-60.htm
Here's what I would do. Leave the height, wheels and tires alone. Get the rust on the rocker panels fixed and put those tube running boards on. Then give the rest to me, lol j/k. I kind of like that style with the billet grille.
It won't melt the housing if you don't have the proper wattage. The problem is that the wiring gets too hot and will melt the wire harness. I had this happen once on a previous car, I didn't know what I was doing.
I think (if it is a dial) there might be a stop inside the switch to keep from dimming too far. If you could crack it open without damaging it you might be able to remove that stop. Unfortunately I have a 2004 so I might not know what I am talking about here, lol.
Just a guess but you could replace that switch with another one. Not totally sure how it is controlled but must are just a reostat (sp) that controls the amount of voltage to the lights in the dash.
Switch to Royal Purple motor oil. I know a guy that owns an Expedition (I know, yuk) and he drives from Michigan to Texas every year for Christmas. He said after RP he gained 3 mpg. Don't know how much this is true but the guy is pretty trustworthy.
Does it shutter at all or does it run rough during idle? I would replace plugs and wires if you haven't already. It's probably something that needs to be done anyway.
I would say just use heat on it. I did the same thing on my 98 Malibu and it's just some kind of gooey like caulk. Very messy stuff but takes a little even pressure all the way around to make sure you don't crack it.
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