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Old 12-10-2020, 12:57 AM   #181 (permalink)
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The Van - '95 Chevy Astro Cl V8 Swapped
Team Chevy
90 day: 10.75 mpg (US)

The new bike - '17 Kawasaki Versys X 300 abs
Motorcycle
90 day: 59.04 mpg (US)

The Mercury - '95 Mercury Tracer Trio
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Going with a cluster from a water cooled bike would be better. I just happened to have the extra KZ1100 one.

Got a new best trip going home from work. 44.76 MPG. I am trying to make it to the top 10 in % over EPA category. Right after last fillup I was at #11, now I'm at #12. Tank is sitting at 41.35 MPG and 204 miles (~1/2 tank).

I did add a separation edge to the passenger side in an attempt to squeeze out a little extra MPG. Removed the pass mirror because I wasn't using it and added a lower grill block.

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Věci získávají svou skutečnou krásu pouze ve vztahu k našemu životu
-Jiří Mucha (1915-1991), Publicist

1973 Fiat 124 Special
1975 Honda Civic CVCC 4spd
1981 Kawasaki KZ750E
1981 Kawasaki KZ650 CSR
1983 Kawasaki KZ1100-A3
1986 Nissan 300zx Turbo 5 spd
1995 Chevy Astro RWD (current project)
1995 Mercury Tracer
2004 Chevy Astro AWD
2017 Kawasaki VersysX 300

https://www.youtube.com/channel/UC6s...LulDUQ8HMj5VKA
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Old 12-13-2020, 03:41 PM   #182 (permalink)
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Cross member /cross tube

The cross tube that supports the steering wheel column from within the dash. Did you remove this on this vehicle??. I notice various auto manufactures use the cross tube to support steer wheel column.

Would be curious if some different lighter material may be used. However getting the steering column support right and geometry right would be a concern. Thanks
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Old 12-14-2020, 02:01 AM   #183 (permalink)
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Join Date: Nov 2015
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The Van - '95 Chevy Astro Cl V8 Swapped
Team Chevy
90 day: 10.75 mpg (US)

The new bike - '17 Kawasaki Versys X 300 abs
Motorcycle
90 day: 59.04 mpg (US)

The Mercury - '95 Mercury Tracer Trio
Team Ford
90 day: 37.79 mpg (US)
Thanks: 114
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Quote:
Originally Posted by TexasCotton View Post
The cross tube that supports the steering wheel column from within the dash. Did you remove this on this vehicle??. I notice various auto manufactures use the cross tube to support steer wheel column.

Would be curious if some different lighter material may be used. However getting the steering column support right and geometry right would be a concern. Thanks
I cut off the extra bracketry and put the main bar back in. It does support the steering column on this. I drilled some new holes in some tabs that were already on the column to re-mount the cluster since it originally used the dash cover/skin for it.

Maybe even getting rid of the bends in the bar could save a little bit of weight since it will use a little bit shorter piece to cross the span. The steering shaft has a u-joint in it so replicating the geometry of the original location shouldn't matter too much. I've been thinking about getting an aftermarket steering wheel so if I do that I can ditch both airbags and lose ~13-16lbs (just a guess)
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Věci získávají svou skutečnou krásu pouze ve vztahu k našemu životu
-Jiří Mucha (1915-1991), Publicist

1973 Fiat 124 Special
1975 Honda Civic CVCC 4spd
1981 Kawasaki KZ750E
1981 Kawasaki KZ650 CSR
1983 Kawasaki KZ1100-A3
1986 Nissan 300zx Turbo 5 spd
1995 Chevy Astro RWD (current project)
1995 Mercury Tracer
2004 Chevy Astro AWD
2017 Kawasaki VersysX 300

https://www.youtube.com/channel/UC6s...LulDUQ8HMj5VKA
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Old 12-14-2020, 02:47 AM   #184 (permalink)
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Join Date: Nov 2015
Location: Indiana
Posts: 608

The Van - '95 Chevy Astro Cl V8 Swapped
Team Chevy
90 day: 10.75 mpg (US)

The new bike - '17 Kawasaki Versys X 300 abs
Motorcycle
90 day: 59.04 mpg (US)

The Mercury - '95 Mercury Tracer Trio
Team Ford
90 day: 37.79 mpg (US)
Thanks: 114
Thanked 217 Times in 159 Posts
Decided to get a little bit more done with the dash deletion sub-project. Stripped the climate control assembly down. I've been using the levers on the ducting to control the output so all I need is the blower motor switch. The assembly wasn't included in the "as removed" weight so this isn't going to contribute to my goal there.

Started at 1 lb 1.55 oz (1.097 lbs or 497.6 grams)


Removed the blower motor switch. I could probably save a few more grams by de-soldering the wires and socket for the bulb and the defrost switch. Ended up with 3.65 oz (.228 lbs or 103.5 g) for a savings of .87 lbs (394.6 g)
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Věci získávají svou skutečnou krásu pouze ve vztahu k našemu životu
-Jiří Mucha (1915-1991), Publicist

1973 Fiat 124 Special
1975 Honda Civic CVCC 4spd
1981 Kawasaki KZ750E
1981 Kawasaki KZ650 CSR
1983 Kawasaki KZ1100-A3
1986 Nissan 300zx Turbo 5 spd
1995 Chevy Astro RWD (current project)
1995 Mercury Tracer
2004 Chevy Astro AWD
2017 Kawasaki VersysX 300

https://www.youtube.com/channel/UC6s...LulDUQ8HMj5VKA
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Old 12-14-2020, 07:49 PM   #185 (permalink)
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Quote:
Originally Posted by M_a_t_t View Post
Maybe even getting rid of the bends in the bar could save a little bit of weight since it will use a little bit shorter piece to cross the span.
IIRC this often happens in those JDM second-hand cars exported to Paraguay while they're converted from RHD to LHD.


Quote:
I've been thinking about getting an aftermarket steering wheel so if I do that I can ditch both airbags and lose ~13-16lbs (just a guess)
Are you also counting the removal of the sensors that trigger the airbag?
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Old 12-15-2020, 12:52 AM   #186 (permalink)
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Join Date: Nov 2015
Location: Indiana
Posts: 608

The Van - '95 Chevy Astro Cl V8 Swapped
Team Chevy
90 day: 10.75 mpg (US)

The new bike - '17 Kawasaki Versys X 300 abs
Motorcycle
90 day: 59.04 mpg (US)

The Mercury - '95 Mercury Tracer Trio
Team Ford
90 day: 37.79 mpg (US)
Thanks: 114
Thanked 217 Times in 159 Posts
Quote:
Originally Posted by cRiPpLe_rOoStEr View Post
Are you also counting the removal of the sensors that trigger the airbag?
I didn't think about the sensors or the control box. Maybe total it could be up to 20 lbs. Wiring, sensors, control box, and the air bags.
__________________
Věci získávají svou skutečnou krásu pouze ve vztahu k našemu životu
-Jiří Mucha (1915-1991), Publicist

1973 Fiat 124 Special
1975 Honda Civic CVCC 4spd
1981 Kawasaki KZ750E
1981 Kawasaki KZ650 CSR
1983 Kawasaki KZ1100-A3
1986 Nissan 300zx Turbo 5 spd
1995 Chevy Astro RWD (current project)
1995 Mercury Tracer
2004 Chevy Astro AWD
2017 Kawasaki VersysX 300

https://www.youtube.com/channel/UC6s...LulDUQ8HMj5VKA
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Old 04-22-2021, 09:06 PM   #187 (permalink)
Ecomodding amateur
 
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Join Date: Nov 2015
Location: Indiana
Posts: 608

The Van - '95 Chevy Astro Cl V8 Swapped
Team Chevy
90 day: 10.75 mpg (US)

The new bike - '17 Kawasaki Versys X 300 abs
Motorcycle
90 day: 59.04 mpg (US)

The Mercury - '95 Mercury Tracer Trio
Team Ford
90 day: 37.79 mpg (US)
Thanks: 114
Thanked 217 Times in 159 Posts
I've been mostly working on my 95 Astro lately so I can use it as a reliable backup. I'm hoping to get my drivetrain swap in the Mercury done before next winter. While it is warm I can ride my motorcycle and use the van if needed (heavy rain, etc) so I will be safe to take the car down for awhile. My plan is in 3/4 steps.
1. Fix the bad rust, just what is necessary to keep it on the road
2. Drive train swap
3. Fix the small rust
4. Work on aero. Both making more permanent setups for current mods and experimenting with new mods.

I've gotten a lot done with the van that has been on the list for awhile now, but I will save that for its build thread. I still want to get that MPG up, but since it's just a toy/hauling vehicle I won't be too serious about it.

Recently though I've done a few things. I re-did the separation edges on the tail lights and bumper as well as add a rear diffuser. I haven't done anymore testing on it yet and I know you usually want to start at the front, but it was much easier to just add a rear one while I was messing with the separation edges. What you don't see in the last picture is some self tappers going into the spare wheel well. I ended up replacing those with a piece of flat stock with 2 bolts welded to it and bolted through the drain plugs in the well. I did put the wheel skirts back on, just don't have a current picture right now.







I just finished a little bit of weight reduction tonight. I added a vacuum gauge (had lying around). I was able to use a hose from the cruise control for it so I didn't have to buy anything. Then I removed the cruise control stuff from the car. Saved 1.35 kg (~3 lbs) not including the addition of the vacuum gauge itself.





Edit:
I did add some tools to keep in the car. I found a partially crushed toolbox (small tacklebox sized one) in the trash at work so I hammered it back into shape and welded a corner where it split open and added a small bottle jack and some simple tools. So the weight savings is pretty much counter-acted now.

Here are some as it sits pictures. Have been consistently getting pretty decent MPG lately.



__________________
Věci získávají svou skutečnou krásu pouze ve vztahu k našemu životu
-Jiří Mucha (1915-1991), Publicist

1973 Fiat 124 Special
1975 Honda Civic CVCC 4spd
1981 Kawasaki KZ750E
1981 Kawasaki KZ650 CSR
1983 Kawasaki KZ1100-A3
1986 Nissan 300zx Turbo 5 spd
1995 Chevy Astro RWD (current project)
1995 Mercury Tracer
2004 Chevy Astro AWD
2017 Kawasaki VersysX 300

https://www.youtube.com/channel/UC6s...LulDUQ8HMj5VKA

Last edited by M_a_t_t; 04-23-2021 at 07:36 PM..
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