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Old 12-20-2018, 04:33 AM   #21
19boneatock88
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

Got a nicer pic of the car, been using it almost daily, but I can’t hypermile as well as normal, I broke my thumb... makes driving a little cumbersome...


...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 02-20-2019, 11:31 PM   #22
19boneatock88
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

WOW, I can’t believe I’ve neglected my thread for so long! It’s been a while lol

I ended up getting new tires with my tax refund (Hankook Kinergy ST 205/65-15) and they’ve been good so far...

My wheel bearings have gotten terribly noisy and I’ve also been using the car for ridesharing to generate extra income... haven’t been tracking mileage so closely since so many of my miles are commercial use now...

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

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Old 10-14-2019, 02:17 AM   #23
19boneatock88
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

I don’t know how, but I’ve neglected my build thread for 8 months?!

So I ended up doing some work on the car over the summer, though I have to figure out how to post pics of it all. I finished my airbox mod, using the large outlet lid with an opened up base. Also I got a cheap header from eBay (blackhorse racing) and installed it (number three exhaust runner needed reshaped) along with a new flex pipe and an all new exhaust system, 2.25” catless downpipe and exhaust with 16” glass pack and a thrush welded muffler poking through the bumper cover under a custom trim plate (thrush logo etched onto it).

I also came up with a new version of my rear wheel skirts and added air separation plates to the rear bumper cover, basically to correct the large radius at the rear bumper for cleaner, less turbulent air separation from the car. I also revised my lower grille block, removing all the tape and making a solid piece of coroplast that’s screwed to the bumper cover and lower grille insert. I even revised my wheel covers themselves for a smoother look and slightly better aero.

I then proceeded to break the living hell outta the thing lol. I ran it on the tail of the dragon with some other Saturn owners (had a blast though, 10/10, absolutely recommend) and broke the roll pin in my shift linkage. Mechanic discovered bad control arm bushings while fixing roll pin, and I did research and ordered the full OTTP control arm bushing upgrade kit (spherical rear and stainless/delrin front), and just as the bushing kit comes in, the transmission starts losing third, and then pukes entirely.

That brings us to now. With 177K on the clock, my car is sitting at the shop waiting on the Cobalt XFE trans (code FY1 F23 manual) to arrive, with the OTTP bushings sitting on the passenger seat. Ain’t life grand?

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

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Old 10-23-2019, 11:23 PM   #24
19boneatock88
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

Got the trans installed but ran into another slight problem I hadn’t anticipated- the 2004 Ion clutch isn’t compatible with the 2009 Cobalt transmission. So it’s getting a new clutch now. Hopefully this marks the last of the problems I have with this car for a while. Having to spend approximately $1000 to fix the issue while also not being able to work due to the car being broken really really sucks

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

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Old 10-23-2019, 11:41 PM   #25
19boneatock88
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

It’s worth noting that I had made a couple changes to the aero in the intervening time. New wheel covers, new rear skirts and new grille blocking...

Pics are from my visit to the tail of the dragon. Yes, a car built for economy can still be fun to drive, I had a blast and the car was far from slowest in the group
Attached Images
File Type: jpg 00B548AC-EFC4-482E-B2AC-10CD190E04B5.jpg (127.4 KB, 4 views)
File Type: jpg 8CFBDB7F-6EED-4048-9BE4-D2689359A38B.jpg (157.4 KB, 5 views)

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

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Old 10-26-2019, 03:54 PM   #26
19boneatock88
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default

Finished my XFE (FY1) trans swap. New clutch meant for the 2009 Cobalt that the transmission came from worked and I’m on the road again!

First of all, wow, this thing is geared so tall! 2000 RPM at a GPS verified 60 actual mph (about 57 indicated) feels super nice, car is quiet even with my catless downpipe and full exhaust. My alignment is wrecked but mileage looks promising all the same. With IATs in the 70F range on the freeway at 60 indicated ,on the flat portions my instant mileage would swing up into the low to mid fifties.

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

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Old 10-26-2019, 04:52 PM   #27
WrightMan
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2004 ION-2 Sedan
Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

Looks good! Are there openings in the rear bumper to allow air to flow through it or just push the flow out wider at the back?

...
2004 Saturn Ion AEM CAI, Aftermarket Head and Taillights, ZZP 2.5" Cat and Custom 2.5" Complete Exhaust
2000 F150 Off-Road 3" Duals and K&N Intake SCT Livewire Tuner
2013 Escape 2.0T AWD CAI

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Old 10-26-2019, 07:23 PM   #28
19boneatock88
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Location: Glenville WV
Posts: 114

2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

Allowing air to break more cleanly away from the bumper cover instead of turbulently over the large radius that is on our bumpers

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(FY1 swap), 178K
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

REWARD EXCELLENCE!

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