First of all, condolences to your friend. Next, glad to hear your smart performed expectedly well on your long trip.
Regarding the A/C, I have a big concern about your well-intended methodology. The reason for my concern is the wind factor while traveling north vs. south. I put 30K miles on a Honda Insight traveling between San Diego and Los Angeles (110 miles each direction), and I routinely monitored my mileage extremely precisely. Often I did the 'run' in both directions with no lag time before making the return. I kept all variables as consistent as possible to try to isolate causal factors that might affect mileage. The Insight has a very low coefficient of drag, so its penalty due to wind should be minor compared to many other cars. However, even under light wind conditions, while keeping the A/C constant in both directions, maintaining equivalent speeds, etc., my NORTHBOUND mileage always exceeded my SOUTHBOUND mileage by 4-10 MPG. (Overall freeway fuel economy would range from 60 to 85 MPG.)
I would not be at all surprised if your mileage variation were due primarily to your direction of travel. With the large frontal area of the smart and not-great coefficient of drag, the freeway penalty running against the wind could account for the difference you experienced.
With that said, I'd love to hear from a ScanGauge user who could make the SAME run in the SAME direction under the SAME traffic, speed, weather, and hill conditions... and see what effect A/C usage has on fuel economy.
Thanks for the report, and many more smart miles to you!