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Old 10-22-2019, 10:02 PM   #301 (permalink)
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Join Date: Jun 2016
Location: WV
Posts: 1,098

IGL - '04 Saturn Ion
Team Saturn
90 day: 56.19 mpg (US)
Thanks: 46
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The saga continues!

So, I got my new clutch kit in the mail, meant for a 2009 Cobalt, so as soon as my mechanic is free again we can try and get this thing on the road...

As an extra note, Iím still working on modding her even while sheís down. What Iím currently working on is a OG VX style trailing edge fender vent to go on when I swap the Redline front clip on (I want the look and its projector retrofitted lights).

I began by measuring and marking off a piece to cut out of the fender (pic included)

Then I cut out the pieces, took them home and transferred the shape roughly into coroplast (my EcoModding material of choice as it reduces the costs of these mods to near free), as well as defining the shape of the part that will actually attach to the fender

Next, I have to cut the filler pieces to hold the vent open and hopefully to a inward curve of some kind (better to extract the fenderwell air with) and then fasten the whole thing together and prepare it to be attached to the fender

Tune in next week for the next episode, when I maybe get to drive the thing and I keep aeromodding the Redline front clip I plan to swap on. Iíve got a bumper cover with way too many grille openings and some fake scoops on the sides which I plan to turn into functional air curtains, and maybe add some kinda air dam if I get a chance

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Old 10-23-2019, 07:20 PM   #302 (permalink)
Master EcoModder
 
Join Date: Jun 2016
Location: WV
Posts: 1,098

IGL - '04 Saturn Ion
Team Saturn
90 day: 56.19 mpg (US)
Thanks: 46
Thanked 253 Times in 198 Posts
Well itís not next week but I have more progress on the aeromodding of my new front clip that I feel good about. I finished my OG VX style fender vents and have them attached to my next set of front fenders, awaiting some paint. Aside from being made from scrap bits of coroplast I donít think they look awful. Hopefully when I have the car up and going I can tuft test my current setup and then the new setup to reflect any differences. Iím fine with them as long as they donít hurt aero any, they look pretty cool as they are, and Iím hoping for a modest 1-2% gain...
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2000mc (10-23-2019)
Old 10-24-2019, 10:52 PM   #303 (permalink)
Master EcoModder
 
Join Date: Jun 2016
Location: WV
Posts: 1,098

IGL - '04 Saturn Ion
Team Saturn
90 day: 56.19 mpg (US)
Thanks: 46
Thanked 253 Times in 198 Posts
It drives again!

The FY1 trans swap is complete. The new clutch works fine, just need to not beat on it too hard until it’s properly broken in. My clutch pedal is junk and gave us issues seeming like a bad master cylinder until we looked closely.

My alignment is wrecked again, it was set based on loose and floppy rubber bushings which the front end no longer has. It also wrecked my front tires so I have two random tires in the proper size in place for now, until I can get it sorted.

The solid bushings make the thing super responsive and super precise and it’s possible to achieve cornering speeds that would terrify any sane individual, however it rides a little more firmly now (oops lol)

The gearing is terrific, though I give up use of 5th in town due to my fifth gear after tire size correction being half a hair more than 30mph per thousand RPM. 25 is just too slow to spin the engine under load in top gear. It’s worth noting that the shift up light no longer functions, presumably because the PCM doesn’t recognize the gear ratios anymore

Picture was taken from my phone mount, at an indicated 60mph, which was an actual speed of 63-64...

With alignment whacked and me sorting clutch issues I haven’t gotten any readings on mileage but it should be great with the car all dialed in
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Joggernot (10-25-2019)
Old 11-06-2019, 12:53 AM   #304 (permalink)
Master EcoModder
 
Join Date: Jun 2016
Location: WV
Posts: 1,098

IGL - '04 Saturn Ion
Team Saturn
90 day: 56.19 mpg (US)
Thanks: 46
Thanked 253 Times in 198 Posts
I now have put 2,000miles on the new setup, though most of that was commercial use. It’s also gotten cold enough that in personal use my engine temps hover in the range of 180F. Mileage is in the toilet as a result. My alignment still needs corrected, but I’m now dealing with issues with my gauge cluster. The lens cracked the other day and some of the lighting has gone off. If I didn’t have a perfectly good cluster in my Ion Redline parts car I’d probably just glue the lens and replace a couple bulbs, but I decided to go down the rabbit hole of swapping the whole cluster. I plugged it in to verify function and all I need is to visit the local GM dealer to get the odometer married to the BCM in my car and I’ll be all good. I did customize the face of my cluster to reflect the mission of my car, more pics when it’s installed and working!

It’s also worth noting that I’ll have them calibrate the speedometer to my current tire size so I can stop guessing at how fast I’m actually going lol

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