Metro,
Right after my last post, I went straight to adding it to the garage!
When I used to race this neon, I got the weight down to 2250 w/ full interior. I think it was ~2150 race weight (take out seats, exhaust system, spare). I plan to get on a scale soon and see where I sit currently. Those numbers stick, but I don't think that was with me in the car at the time. On top of that, This car will have a SOHC over a DOHC head, further removed AC and PS components, more deadener and insulation removed, added light-weight stereo system, nicer seating, etc. Lots of changes in both directions.
Being a daily driver now, I am putting in some deadener (very mild amount, covering ~25% of any flater sheet metal with resonating potential, as per instructed by sounddeadenershowdown.com) and using the double-bubble foil insulation throughout the entire car for both acoustic and thermal insulation. This shouldn't add but a few more pounds in, though, as the deadener is minimalistic and the insulation is very light weight.
Anywho, I actually took out each item back in '04 and documented what each piece weighed. I hope the length list isn't an issue (I tried SPOILER tags, but seems this forum doesn't support that). I'm sure there are other things that are added and/or removed in since, but it's been too many years. I still have a few tricks up my sleeves to reduce the weight, but all in good time.
Quote:
Air conditioning system (heat exchanger = 5.75 lbs, compressor = 15 lbs, piping etc = 3 lbs, block to AC bracket = 2.5 lbs, metal box at firewall = .75 lbs) --27 lbs
Rear bumper support (metal = 16.75 lbs, foam = 2 lbs) --18.75
Battery (28.5 lbs vs 15.25 lbs) --13.25 lbs (?)
Trunk modifications (Cut center brace in trunk --4 lbs, outer bracing --4.25 lbs, trunk arms --4.5 lbs) --12.75 lbs
Airbag system (computer = 2 lbs, pass bag = 9 lbs) --11 lbs
Floor sound deadener (front floor = 2 lbs each X2, Rear floorboards = 2.5 lbs, under rear seat = 2 lbs, under front seats = .75 each X2, front/center center consol = .05 lbs, rear center consol = 0.25 lbs) --10.75 lbs
Sunroof extras (plus bolts) --10.25 lbs
Trunk Carpet --10 lbs
Base rear seat (21.75 lbs VS 31.25 lbs) --9.5 lbs
Rear Door modifications (Rear door bracing = 4 lbs each X2, Cut metal from rear doors = 0.625 lbs each X2, Remove rear door lower dust covers -- 0.25 lbs) --9.5 lbs
Surfboard spoiler --7.5 lbs
Console weight --7.25 lbs
Sound insulation (under front floor = 2.25 lbs, under seat and rear floor board = 2 lbs, under center consol = 1.5 lbs, under dashlid = 0.5 lbs) --6.25 lbs
Side rub strips --6 lbs
Spare tire change (1st gen = 28.5 lbs VS 2nd gen = 23.25 lbs) --5.25 lbs
Evap System --5.25 lbs
Front motormount weight --5 lbs
Stock CD/Tape player --5 lbs
Misc nuts, bolts, screws, clips, insulation, etc -- 5 lbs (?)
Replace Steelies with aluminum* -- 5 lbs (?)
Drivers radiator fan --4.5 lbs
Spare tire cover --4.5 lbs
Seat belt brackets (2.125 each X2) --4.25 lbs
Lower 1/2 firewall blanket --5.25 lbs
Sport front seats to base front seats (2 lbs each X2) --4 lbs
MPx UDP (5.25lbs vs 1.5lbs)* --3.75 lbs
Hood brace (2 X-Braces and center = 2.75 lbs, rear = 1 lbs) --3.75 lbs
Rear speakers (1.75lbs each, X2) --3.5 lbs
Door speakers (1.75 lbs each, X2) --3.5 lbs
Remove door plastic skin deadener (0.75lbs per door X4) --3 lbs
Replace intake --3 lbs (?)
Cruise Control system (under hood) --2.5 lbs (?)
Front door Foam block (1.25 lbs each, X2) --2.5 lbs
Driver's side under dash bracket --2 lbs
Trunk rubber seal --1.75 lbs
Passanger's side glovebox bracket --1.75 lbs
Steering wheel weight and bracket --1.75 lbs
Sound deadener on roof --1.5 lbs
Sound deadening insulation under dash lid --1.5 lbs
Passenger side power mirror -- 1.5 lbs
EGR system --1.25 lbs
Winshield washer fluid system --1.25 lbs
Wiring harness gutting --1.25 lbs
Fog lights (0.5 lbs each, X2) --1 lbs
Trunk springs (0.5 lbs each, X2) --1 lbs
Front door brackets (0.5 lbs each, X2) --1 lbs
Dash Speakers --1 lbs
Moddify battery tray --1 lbs (?)
Overhead handles (3) and hangers (1) --1 lbs (?)
Front Airdam --1 lbs (?)
Ashtray + bracket --1 lbs
Seat belt dust covers + thin metal plates (.5 each, X2)= --1 lbs
Underhood insulation --0.75 lbs
Underhood battery scoop --0.75 lbs
Upper rear seatbelt brackets (.375 lbs each) --0.75 lbs
Port and polish intake manifold and bored stock throttle body --0.5 lbs (?)
Underhood weather stripping --0.5 lbs
Strut caps (rear, 0.125 lbs each) --0.25 lbs
Cut out trunk light metal, bulb --0.25 lbs
Front door sound deadener (0.125 each) --0.25 lbs
-Total = ~266.75 lbs
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Some of the more extreme things I did that I did not list was things like using zip ties over screws/bolts where applicable, cutting down lengthy bolts... gees I know it was desperate times for that last little bit of speed back in those days. I chose this shell simply because of all the work already done in weight reduction. I want to try to keep this car as light weight as possible, but still make is a pleasure to drive every day. Some compromises will be made, but since it's mostly a city driving car, I think low-weight will still be a top priority, only trumped by aerodynamic modifications (as that obviously will add some weight).