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Old 10-22-2019, 09:02 PM   #301 (permalink)
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IGL - '04 Saturn Ion
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90 day: 56.19 mpg (US)

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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, 06:20 PM   #302 (permalink)
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Join Date: Jun 2016
Location: WV
Posts: 1,143

IGL - '04 Saturn Ion
Team Saturn
90 day: 56.19 mpg (US)

grayOS (personal use) - '19 Mitsubishi Outlander Sport ES
90 day: 30.71 mpg (US)
Thanks: 50
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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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Old 10-24-2019, 09:52 PM   #303 (permalink)
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Join Date: Jun 2016
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IGL - '04 Saturn Ion
Team Saturn
90 day: 56.19 mpg (US)

grayOS (personal use) - '19 Mitsubishi Outlander Sport ES
90 day: 30.71 mpg (US)
Thanks: 50
Thanked 276 Times in 212 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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Old 11-05-2019, 11:53 PM   #304 (permalink)
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IGL - '04 Saturn Ion
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90 day: 56.19 mpg (US)

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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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Old 01-16-2020, 04:42 AM   #305 (permalink)
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Join Date: Jun 2016
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IGL - '04 Saturn Ion
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90 day: 56.19 mpg (US)

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So I wanted to update on this car. Couldn’t calibrate speedometer or swap the cluster (local dealer couldn’t do it, might look for another one). Working on modding bumper cover, debating between air curtain built into side vents, or a simple plastic air deflector at the leading edge of the wheel well. I’ve also decided to add heat extraction vents to the hood, both to reduce drag and to reduce coolant temps during spirited/aggressive driving, especially since the new bumper cover has less grille area than my current one (if you count the unblocked upper grille), being that it has no upper grille.
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Old 01-16-2020, 10:15 AM   #306 (permalink)
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Quote: "...I’ve also decided to add heat extraction vents to the hood, both to reduce drag and to reduce coolant temps during spirited/aggressive driving, especially since the new bumper cover has less grille area than my current one (if you count the unblocked upper grille), being that it has no upper grille."

I installed a couple of louvers in the hood of my Mazda3, mostly to increase longevity of the battery in my semi-tropical climate. Besides, I was going after the classic XKE Jaguar look. :-)

When I installed the hood vents, I also added a gauge under the hood to track temps there. I don't know what the temps were before the louvers, but with them the engine bay temps are about what the ambient temps are. IE, when the car is moving, if it's 50F outside, its 50F under the hood. If it's 90F outside, it's 90F under the hood. Until, of course, you stop the car. Then, the under-hood temps will temporarily rise to maybe 150F or so until the hot air is able to escape on its own without the aid of the forward movement of the car.

I know that it is arguable that keeping temperatures under the hood high is better for fuel economy, but I can't tell any difference. Besides, I think cooler temps in the engine bay are better not only for the battery, but also the computers, sensors, belts, hoses and plastics that are subject to degrading heat from the engine.

The hood venting doesn't affect my engine coolant temps. The engine coolant is controlled by the thermostat, and coolant temperatures haven't changed at all for me. However, if I covered the grill (which I don't), I'm sure the hood louvers would supply some amount of relief should coolant temps rise due to the air blockage.
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Old 03-10-2020, 02:36 AM   #307 (permalink)
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IGL - '04 Saturn Ion
Team Saturn
90 day: 56.19 mpg (US)

grayOS (personal use) - '19 Mitsubishi Outlander Sport ES
90 day: 30.71 mpg (US)
Thanks: 50
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Been working on the car a bit lately. I picked up a rare-ish set of wheels meant for a mid nineties Saturn SL2. Supposedly only 14lb and decent aero even before blanking the holes out/attaching a pizza pan to them. Less rotational mass is always a win!

Iíve also worked on mirror delete blanks. Got the shape cut out of coroplast and refined to a decent fit, just working on mounting them.
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Old 03-17-2020, 02:51 PM   #308 (permalink)
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Black and Green - '98 Honda Civic DX Coupe
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Quote:
Originally Posted by 19bonestock88 View Post
.... wheels meant for a mid nineties Saturn SL2. Supposedly only 14lb...
Weigh those puppies before you put tires on 'em. Let's find out how much they weigh!
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See my car's mod & maintenance thread and my electric bicycle's thread for ongoing projects. I will rebuild Black and Green over decades as parts die, until it becomes a different car of roughly the same shape and color. My minimum fuel economy goal is 55 mpg while averaging posted speed limits. I generally top 60 mpg. See also my Honda manual transmission specs thread.

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Old 03-24-2020, 09:17 PM   #309 (permalink)
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Join Date: Jun 2016
Location: WV
Posts: 1,143

IGL - '04 Saturn Ion
Team Saturn
90 day: 56.19 mpg (US)

grayOS (personal use) - '19 Mitsubishi Outlander Sport ES
90 day: 30.71 mpg (US)
Thanks: 50
Thanked 276 Times in 212 Posts
Iíve been away for a while, but that doesnít mean progress has stopped. Iíve somewhat solved mounting for my mirror delete blanks and have been cruising around with no mirrors. The mounting isnít perfect, the blanks need weatherstripping on the backside, and the white coroplast screams ďself moddedĒ but they seem to work. I even grabbed the interior corner trim from a higher level Ion that had power mirrors so I donít have a hole in my corner trim for the adjuster.

Iím also in process of making pizza pans fit over the wheels I got (still havenít been weighed bc I donít have a scale)...

...aaaand, Iím delving into engine tuning by means of tricking the sensors. A friend made a circuit to put a potentiometer in line with the MAP sensor and the thought is to trick the PCM into reading more vacuum than it has, in order to advance timing. Being that it also affects air fuel ratio at wide open throttle (to be fair it skews the mix everywhere but in closed loop the car will use the oxygen sensor to correct) I have only made slight adjustments and have been logging data and watching fuel trims to make sure the car can still correct enough to have a proper air/fuel ratio. So far though Iíve gained (I think) 1.5-2 degrees of timing at cruise, 1 degree throughout the range at WOT, and like 6-8 degrees at idle. The car idles normally and drives fine around town and on the road, but being more responsive/powerful. Since this affects the UltraGauge readings I have no way to say for certain what it does to economy, it seems about the same on the gauge but Iíve no way to verify itís accuracy. My tank average is shot due to having a lot of long WOT pulls on it from the tuning, and to be honest I just donít drive it much. With my work all but shut down I donít really drive much at all at the moment
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Old 03-25-2020, 10:01 AM   #310 (permalink)
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Did you verify that less signal from the map sensor decreases fuel quantity? I am under the possibly mistaken impression that map sensors work in reverse, the less vacuum measured the more signal voltage output.

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