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Old 09-25-2018, 12:14 AM   #1
19boneatock88
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default 19bonestock88’s 2004 ION-2 sedan “Green Line” build

I wanted to track the build of my car here as well... I’ll cant link link to what I have currently yet, but I will soon, and then add more in later posts




Not gonna get lean burn at cruise like I originally wanted (can’t piggyback tune for it) and likely not gonna make it a BAS hybrid like Buick LaCrosse (e-assist), but do plan on cleaning up aero as much as possible and eventually swapping a higher compression L61 and a FY1 code F23 trans (3.63FD vs the M86 at 3.84)

Stay tuned for link to original build thread and fuel log

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 10-01-2018, 11:30 AM   #2
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 just occurred to me that I can now link to my original build thread and fuel log... I did draw a little inspiration from the “Ion XFE” build on here, which eventually led me to join...

Build thread

https://ecomodder.com/forum/showthre...ild-35257.html

Fuel log

https://ecomodder.com/forum/em-fuel-...ehicleid=10025

The car isn’t parked for now, due to having to use wife’s car and only being able to insure one at a time for the moment, but I’m currently sorting out a no crank issue and working on more mods to get even better mileage... before I stopped driving it, my 90 day average was 48.7mpg... next summer I’m hoping to get at least 52-55mpg

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 10-01-2018, 01:18 PM   #3
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2004 ION-2 Sedan
2006 ION-2 Quad Coupe
Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

Was working on rear wheel skirts the other night after I removed seats, as I had this mod before on a car and it gave me a solid 3-5% increase in mileage at cruise (2% engine load reduction at 55mph)...

I made some steel brackets that will attach to the inner fender using the push rivets holding it in... the skirt, which is made of coroplast, will attach to the brackets with push rivets to facilitate easy removal...
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File Type: jpg 90A429AD-4AF0-450E-9C7A-F6FDAFD8F92A.jpg (105.1 KB, 2 views)
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...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 10-01-2018, 07:21 PM   #4
duece9s
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

i have a feeling the area below the stock rear bumper is a parachute

...
06 ion 109k
12" L7/mids/tweets
Stock batt + XP950 in the back
fuelly: http://www.fuelly.com/car/saturn/ion/2006/blueion/652913
37.6 best mpg/478 miles

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Old 10-01-2018, 08:08 PM   #5
19boneatock88
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

It absolutely is, and I plan to make a diffuser from 10mm coroplast to cover the area... the issue is that the bumper cover doesn’t hang as low as the trunk floor so I have to get creative on how to make it without it being overly ugly or “ricey”, and have it clear an exhaust

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 10-01-2018, 09:49 PM   #6
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

i tried to mock something up a while ago

http://www.imagebam.com/image/89380a429247272

...
06 ion 109k
12" L7/mids/tweets
Stock batt + XP950 in the back
fuelly: http://www.fuelly.com/car/saturn/ion/2006/blueion/652913
37.6 best mpg/478 miles

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Old 10-02-2018, 02:14 PM   #7
19boneatock88
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

After looking at the picture, I just have to ask,

1. Did it help any with fuel mileage, particularly on the highway?

2. What did you make it out of?

Needless to say you’ve given me a new perspective on how to make my diffuser...

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 10-10-2018, 06:55 AM   #8
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

Got bored waiting on my starter and swapped the Recaro seats in, sourced from my non running Redline... they’re stained pretty badly but far more comfortable than the original seats... while everything was out I had the chance to do a really thorough vacuuming too

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 10-29-2018, 10:24 PM   #9
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

Quote:
Originally Posted by 19boneatock88 View Post
After looking at the picture, I just have to ask,

1. Did it help any with fuel mileage, particularly on the highway?

2. What did you make it out of?

Needless to say you’ve given me a new perspective on how to make my diffuser...
i was hoping to use some cloth and resin (basically fiberglassing) but it didnt work out. you could do it that way, or like any diffuser seen on any GT racecar. have you noticed driving on the highway in the rain that the rear window doesnt get wet? i wonder if the air recirculates a lot around the back window. i wonder if adding vortex generators to the roof just infront of the rear window would help efficiency.

https://youtu.be/eP-YUDe9HF0?t=154

...
06 ion 109k
12" L7/mids/tweets
Stock batt + XP950 in the back
fuelly: http://www.fuelly.com/car/saturn/ion/2006/blueion/652913
37.6 best mpg/478 miles

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Old 11-02-2018, 12:52 PM   #10
19boneatock88
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

I am still debating on whether or not to add fences to my diffuser when I build it... the fences generate a rolling vortex under the car, which may/may not help significantly, but I wanna hold off on making it until I’ve upgraded my exhaust, for fear of having to re-work it later... I’d also like to make a rear sway bar beforehand if I can get the metal to do so...

I experimented with vortex generators on the 07 Malibu I had a couple years back but found a negligible effect, but considerably more mocking from onlookers so they came off... I also tried a 14” rear window visor on my Saturn, angled down at what I thought was a 8-10* angle to the roof but it caused much more drag, as evidenced by my coasting distances shrinking... I’d like to tuft test the rear window and see if there is any airflow attachment at all before I try vortex generators again...

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 11-02-2018, 01:41 PM   #11
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

48 mpg is astounding! For any car. As to vortex generators, I believe some more background info may be needed before vortex generators are considered.

In high school, I had aerodynamics classes including laminar flow as well as mathematical equations for lift, drag, coefficients of drag, horsepower, two dimensional x-y plotting long before computational fluid dynamics and super computers eliminated slide rules and millions of hand calculations, blah blah blah. Back in the late '60's Mr. Hall stated that unless airflow doesn't exceed approximately 200 mph, winglets weren't efficient. Fast forward and many commercial airlines tweaking for best fuel burn have winglets. The vortex generated is drag before winglets tweaked high speed airflow to reduce drag. A close look at Formula-1 cars shows aerodynamics everywhere to take advantage of keeping these beasts stuck to the ground in high speed turns that are moving way less than 200 mph but effective enough to warrant tire compounds as soft as pencil erasers. For every day daily driving, vortex generators may be useless. Where they do work seems puzzling to me, is on the upper trailing surfaces of some wings and maybe tail planes where it helps to enhance airflow. Examine some wings for vortex generators. Remember, they're designed for high airflow speeds. For daily drivers, probably ineffective. A key to studying car design and airflow for the lowest coefficient of drag is to study aerodynamics and review smoke streams. All car designers at one point or another review how aerodynamics affects how a vehicle slips thru the air stream. Try pushing a 4x8 piece of plywood thru the air then lay it flat to understand how drag is created by surface area. Reducing frontal area is only one part of reducing drag. Wheel covers and under chassis covers also plays into drag. Lastly, the laws of diminishing returns may be lost on some insisting on every mod possible but ignore the point of zero returns when mods become more drag than reducing it. Just some food for thought.

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Old 11-02-2018, 02:29 PM   #12
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

I have however done some more work on the rear wheel skirts, finishing the panels themselves by adding the stiffening rib to the bottom and attaching the brackets to the car... I’m literally just a few push rivets away from having them mounted...

I’ve also done some work to further upgrade the intake on the car... anybody familiar with the 03-04 Ion knows the airbox outlet is a tiny oval that’s maybe 2” tall and 3.5” wide... what I’ve done is cut the original outlet off the airbox lid and open it up to accommodate a 3.5” round tube (I used extruded thin wall HDPE pipe)... it *should* flow a lot more than the factory setup, without drawing warm air from the engine bay(though that aspect usually does boost mileage)...
Attached Images
File Type: jpg D73C3AE7-1DD6-4ADC-96BE-4F18799FB966.jpg (113.6 KB, 2 views)
File Type: jpg 57963375-9DDF-4294-B017-7E75D9B44E69.jpg (111.4 KB, 1 views)
File Type: jpg 8C9D88DE-E50B-4D58-B2B0-116042AC0E1B.jpg (131.1 KB, 1 views)

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 11-03-2018, 01:41 PM   #13
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

FDryer, you make an excellent point about diminishing returns and ROI...

For sake of calculating, I ran the cost of driving my car for 300mi, with costs plotted at the EPA combined rating of 26, and 40, 48, 52, and 55mpg...

At the EPA combined rating the travel would use 11.53 gallons or $33.32 at gas prices local to me, and at an even 48mpg(which I’ve passed shortly before I parked the car) the distance would take 6.25 gallons, or $18.07... increasing to 55mpg(my ultimate goal for the car) uses 5.45 gallons to cover the 300mi and would cost $15.75...

Basically I’ve saved $15.25 per tank bringing mileage up to where I had it this summer, based on the EPA rating, but to bring mileage up to 55mpg would only save me an additional $2.32 per tank...

The biggest gains that are possible for my car, I’ve alteady realized just through driving technique and trip planning, and some more gained with repair/modding on the cheap... I’m *almost* out of low hanging fruit to pluck, meaning that mods in the future will cost way more and provide less gain... I’m almost constantly broke, which has necessitated the modding/ hypermiling, and I simply don’t do mods that I can’t get done cheap enough to pay me back in the first couple tanks of fuel...

Not that I’m gonna stop trying for 55 though...

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 11-03-2018, 02:31 PM   #14
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

My guess is you're most likely at the limits of mods where your roi diminishes. Achieving 55 mpg with every tweak between driving habits, optimum engine/xmission maintenance and keeping the lowest rpm is about all you can do. In the S-series forums, one member ran experiments with the intake air temperature sensor - it affects air/fuel mixtures similar to the engine coolant temperature sensor. Substituting various resistors on a set loop on his drive to control as many variables returned a minimum of 45 mpg. The resistor substitution worked best with a warm engine, not on cold engine warm up. Since he knew cold engine running demands rich fuel mixtures, a leaned out engine faltered until it began warming up. In the end, he decided on a switchable set of resistors to allow just enough richening during cold engine startup and manually switching in other resistors to force leaning out a/f mixtures. Altering his first morning drive to minimize stalling helped. He also created a hot air intake, using exhaust manifold heat to supply hot air to help lean out fuel mixtures. Surpassing 50 mpg was his goal. No aerodynamic mods. Maybe tires inflated to higher pressures to lower rolling resistance.

I think you're accomplishing the same goals.

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Old 11-03-2018, 07:50 PM   #15
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

You bring up another good point, maintenance... while I have tried to keep the oil changed every 3-4k (Pennzoil high mileage 5W-30 and ACDelco filter), I’ve not touched the trans fluid and the spark plugs are factory original... I should probably blow out my air filter when I swap the airbox lid, I don’t remember doing so...

My record tank was 51.1mpg (shortly after my zero toe alignment and FE5 control arm swap) so in theory 55 should be doable at least once, but I want to be able to consistently nail it...

Tires are 5.3% oversized and ran at 55psi (they never lasted due to alignment issues so it didn’t matter if the pressure messed up the wear)

The only thing making the aero modding cost effective is that I’ve obtained all my coroplast for free, and any strapping tape that I’ve used for grille blocking or holding on coroplast has been free...

I rolled the lowering springs into a suspension rebuild with FE5 dampers, though technically they haven’t paid for themselves yet...

Maybe some Redline MT-90 in the trans will help? The synchro is weak on 3rd and I get a crunch going down into 3rd or when I go up into 3rd at too high of RPM

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 11-09-2018, 12:42 AM   #16
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

I revised my trunklid extension again... basically the tape was getting loose again and I didn’t wanna pile even more on, so I took it all off and cut new pieces... I made some big side plates for it and made bigger reinforcements, and instead of using tape for the seams I used hot glue (though I plan to reinforce with tape at some point), and attached the whole thing with sheet metal screws (going into the plastic endplate of the trunklid)

Pics coming soon, I tried taking some but due to poor lighting in my garage they didn’t turn out...

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 11-13-2018, 10:21 PM   #17
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

the only model i could find online was a QC.

https://youtu.be/U-Rh-GAd94Q

disclaimer:
-radiator inlet closed
-underbody is flat
-60mph

...
06 ion 109k
12" L7/mids/tweets
Stock batt + XP950 in the back
fuelly: http://www.fuelly.com/car/saturn/ion/2006/blueion/652913
37.6 best mpg/478 miles

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Old 11-17-2018, 03:47 PM   #18
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

That’s pretty cool, now I know how the air behaves over my wife’s car...

From how high up the air detachment starts it looks like we’ll have to eventually look into vortex generators(like the EVO) in the future...

...
Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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Old 12-08-2018, 05:04 AM   #19
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Default Re: 19bonestock88’s 2004 ION-2 sedan “Green Line” build

I got to drive my car to work the other day, after having fixed the battery issues and patched the tire (picked up a screw)... I was able to grab some pics of my wheel skirts and new spoiler attached to the car, in some half decent lighting...
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Jerama- WV

2004 Saturn Ion-2 sedan
L61/F23(M86), 139k...
Too many mods to list in sig...

“Stock” is nowhere in my vocabulary...

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