Restoration/modding existing car for MPG vs buying new

DrMrLordX

Lifer
Apr 27, 2000
21,813
11,167
136
I already posted about this in this thread, but I figured I'd make my own topic to avoid total thread-jacking (though this thread feels a bit redundant . . . oh well).

Anyway, I'm looking at a new car in about 1-2 years. I really want something that can get me combined MPG of 40+, or at least 50 highway, without having to drive like too much of a grandma to get there.

The obvious solution is to buy new, and the candidates that I am considering are:

Toyota Prius
Pros: Combined 45 mpg is easily obtainable, with better fuel economy coming in city driving for some motorists.
Cons: $22k for the base model (what I would get), and . . . it's a Prius. The chance that Prii will sell for well over list in the event of another gas price spike is also quite high, so price and availability may be quite bad once I get around to buying.

Chevy Cruze
Pros: The 1.4 litre turbo version, which is supposed to produce 40 mpg combined, may be cheaper than the Prius. It also only weighs something like 2400-2450 pounds or so, so all kinds of minor engine/transmission mods may be possible to improve fuel economy even further. I've really been looking forward to this one.
Cons: No clue what the 1.4L model will cost, but supply/demand metrics will probably push it over the comfortable econobox price level. Just look at what VW charges for the TDI. Will also require 93 octane fuel (most likely) unlike the Prius, though, with fuel as expensive as it is now, or as expensive as it could be, an extra $.20-$.25 per gallon on fuel wouldn't be a nightmare. And, as with the Prius, price/availability on the Cruze will probably be awful if fuel goes back up to $4/gallon or higher.

Ford Fiesta:
Pros: Everyone seems to love this car, and watching Jeremy Clarkson storm a beach in one was awesome. Seems well-balanced, fast, and reliable. Base model will supposedly only be $14k once the 2011 model is released in the states, though I don't know if that model will be the best for fuel economy of all those that will be made available (hopefully so).
Cons: The Fiesta is advertised as getting 28/38 (or rather, it is advertised as looking like it will generate those mpg numbers when it is finally released), which is pretty close to what my current vehicle can muster, so I'm not sold on the idea of getting the Fiesta. It may be one tune away from being an awesome fuel-sipper, but I don't know how much I really want to buy a new car and then tune/mod it. At least at the price of $14k, I wouldn't feel as squeemish about doing so.

Jetta TDI:
Pros: VW claims it can get 58 mpg on the highway. Okay, I'll give them the benefit of the doubt, even if the EPA says 30/41. Also, unlike the Cruze and Fiesta, you can actually buy one of these things today.
Cons: $22k for an econobox. Bleah! Plus it's a VW. I don't hate them or anything, but the failure rate on past VWs has me nervous. For the money I think I'd be better off with a Prius. Modding/tuning a TDI could be very interesting, however . . .

The other options involve rebuilding/modding an existing car to make it a fuel-sipper competitive with those that will be available 1-2 years from now, hopefully at a lower price point.

'04 Saturn Ion 1 Automatic
Pros: I own it, so I wouldn't have to put up any cash for the base car (and its fully-paid too). It also weights 2650 pounds wet and has a coefficient of drag of .32, which isn't too bad in either department. Not incredible, but not bad. There mere fact that it gets so much better fuel economy on the highway at speeds up to 75 mph (faster than that and fuel economy starts to drop off) seems to be an indicator that drag isn't what's holding the car back from better fuel economy. And I really like the engine for a number of reasons. It's reliable and, according to all outward appearances anyway, seems to be in excellent condition, at least as far as the body; frame; and undercarriage are concerned.
Cons: It's an auto, and fuel economy really seems to suffer in start/stop scenarios. If I did mod the car for fuel economy, I'd almost have to go manual. Finding ways to reduce the car's weight could be difficult since it is already so spartan. And, since it's a Saturn, availability of parts is not fantastic (they're out there, but not in great numbers, and some are stupidly expensive). Getting an intake, exhaust, and some other parts might require custom jobs and that could get expensive. The stock ECU would have to be replaced since the ECU for the 2.2L '04 Ion is still not supported by anyone, yet the one obvious replacement ECU (MegaSquirt 2) apparently doesn't support the ignition properly (or so I've read), forcing kludgey work-arounds just to use the replacement. The engine could be entirely replaced but I'd hate to toss one of the parts of the car that I like the most. Also, one of the most potentially-bedeviling problems from modding this car is that, as it is currently set up, the engine seems to hit an efficiency sweet-sport between 2k and 3-3.5k rpm; going to taller gears on a new transmission might make it very difficult to stay in that RPM range without significantly reducing the amount of power the engine produces within that RPM range. It might be possible to shift the engine's maximum efficiency range downward (or widen the power band a bit) by messing with intake, exhaust, and other things, but that might not be simple (custom intake/exhaust/throttle body/intake manifold/heads/cams, $$$). And, to further complicate matters, I've considered going the forced induction route (small turbo) to improve volumetric efficiency on the 2.2L, but getting the turbo to spool up at low RPMs could be quite a challenge. A twin turbo arrangement might fix that but that would be weird and expensive. Overall, if I make poor choices when choosing how to mod the car and when choosing what shop(s) to patronize, I could be out a lot of money. Plus there's the matter of trying to get a local credit union to help me finance the whole thing, which might not be easy. Trade-in value on the Ion would vanish (not that it's worth all that much now). The Ion has a suspicious vibration/rattle problem at high speeds, and I don't know what's causing it, though that tells me that it may be nearing time to get rid of the car (hinting that a restoration/mod effort could involve some unwanted repairs to parts I am not currently considering modding/replacing anyway).

Honda Civic (any year)
Pros: Civics are commonplace vehicles that are often well-built, lightweight, and thrifty on the fuel budget. Plus I know a guy who loves Civics and is good with fiberglass who can allegedly get a Civic down to 2k pounds (how streetable it is in that state is anyone's guess) and knows a good bit about Honda engines and engine modding/tuning. Honda Civics from the right model year are notorious for being reliable and durable cars, and the fact that they tend to rev high would make their engines a fairly good candidate for efficiency-through-forced induction. Due to availability of parts and other factors, modding a Civic should be a lot less expensive than modding my Ion, and in the case of a Civic that already has a manual transmission in it, I might not even need to swap out the engine OR transmission to do what I'd like. In fact, I would think a Civic with a D-class engine would do nicely. As an added bonus, I could keep my Ion as a daily while having work done on the Honda.
Cons: I don't own one, and finding one that hasn't had the crap beat out of it and is still affordable is a tad difficult. I'm sure there's one out there that would be right for my intended application but it could take awhile to find it, and financing the purchase of a used vehicle from a private party could be difficult. A Civic with serious problems in the body, frame, or undercarriage could cost so much to restore that it would eliminate the savings to be had from not necessarily needing to swap in a new transmission (or go to coilovers as a suspension upgrade, or go to a buggy standalone ECU, or any of the other wacky stuff I'd have to do to the poor Saturn). In any case, a full rebuild of engine and transmission would probably still be necessary, not that I would anticipate anything less from the Saturn as well (and a rebuild would make modding things easier anyway). The Civic's reputation as having a high trade-in value would be shot all to hell.

Other options include a late-model Fiero (!!), a 4-cylinder Camry from the early 90s (92 or earlier), a Suzuki Cultus variant (Geo Metro, etc), a used Insight (good luck), a used Yaris, or something along those lines. Given the fact that I am considering engine/transmission rebuild I'm open to many options that don't involve buying a car with serious rust problems or undercarriage stress/damage issues (don't want an axle failing on me while I'm driving along). I also prefer vehicles with modern engines since efficiency has gone up considerably on gasoline engines in the last 10 years or so (hell, look at what GM is doing with EcoTecs now versus what my 2.2L from '04 can do), though nothing says that I can't just drop a 1.3L TDI engine into something and call it a day. Well, aside from the expense involved but I digress.

If anyone has any feedback that might help me get going in the right direction, please let me know. In particular, I'd like to hear from someone who has built a DIY fuel-sipper (hands-on or through a shop) or knows of someone that has. The Insight with the 1.3L TDI engine is an excellent example of what can be accomplished with the right plan and execution, not that I expect to do anything quite that awesome myself. I have no idea how much that cost them in the end to do that.
 

zerocool84

Lifer
Nov 11, 2004
36,041
472
126
I would never recommend anyone to buy a hybrid. It takes at least 5+yrs for the average person to recoup the extra cost they spent on something like a Prius when they could have gotten something comparably equipped that still got good mpg. It's not like you can even get one for a good price either. They are insanely priced. Just get something like a Civic, Focus, or the like and put the money into something else.

The thing is that you don't even say what type of driving you do or how long you usually keep cars or plan on keeping your next one?
 

DrMrLordX

Lifer
Apr 27, 2000
21,813
11,167
136
Originally posted by: zerocool84
I would never recommend anyone to buy a hybrid. It takes at least 5+yrs for the average person to recoup the extra cost they spent on something like a Prius when they could have gotten something comparably equipped that still got good mpg. It's not like you can even get one for a good price either. They are insanely priced. Just get something like a Civic, Focus, or the like and put the money into something else.

The thing is that you don't even say what type of driving you do or how long you usually keep cars or plan on keeping your next one?

Agreed on the price of the Prius. I fear that it has set a benchmark for what a fuel-efficient econobox is "supposed" to cost in the present and future (read: will greatly affect what Chevy thinks they can get for the Cruze, what Ford thinks they can get for the Fiesta, etc). It should come as no surprise that the Jetta TDI and Prius have the same base MSRP. Gah.

As for what type of driving I do, I do every type of driving possible short of towing things. I regularly drive up a mountainside, I deliver newspapers (on said mountain), I do highway driving, I do mixed driving, I do stoplight-to-stoplight city driving, etc. I even sort of go off-road since one of my paper routes has some really crappy gravel driveways that can easily eff-up alignment and would probably be hell on mag wheels if I ever got anything other than the strongest forged stuff.

I usually keep cars until they commit suicide (which is what my last car, a Mercury Tracer, essentially did) or until the cost of maintenance outweighs a monthly car payment. Usually. My Ion has served me well, and would probably last another 3-4 years if I treat it nicely, but I'm not sure how much longer I want to be married to its 20 uphill/27 city/30 mixed/34-38 highway fuel economy. For most people, that's pretty good, but I want something better than that. That desire, in and of itself, is not 100% rational, but I really don't want to be over a barrel if/when the gas prices go up again.

Also, seeing stuff like this is always inspiring, even though I doubt I could live with aero quite like that. Parallel parking that thing must be a bitch. Or maybe it isn't?
 

SearchMaster

Diamond Member
Jun 6, 2002
7,792
114
106
What's your motivation exactly? If it's just saving money, just buy the cheapest car you can find that averages 30+ MPG and you'll come out ahead in the long run. There's just about no way to recoup your initial investment in a new Prius/Cruze/TDI/Fiesta/whatever versus a 3 year old Civic/Corolla/Focus/whatever unless you drive ridiculous numbers of miles every year.

It sounds like you're probably more interested in just tinkering with the car to maximize mileage. There's a guy here (Uhtrinity) with an older Insight who is getting like 80+ MPG through battery additions, etc. and is adding (or has added) plug-in capabilities to it. It seems like a hybrid would be better for this type of tinkering than a non-hybrid.
 

MiataNC

Platinum Member
Dec 5, 2007
2,215
1
81
Anything you drive with a payment is costing you money that could be better spent on whatever additional gas your paid off car is using. If your current car gets decent mileage (@20city/@25hwy or better) you will save a LOT of money keeping what you have.

Few cars get "advertised mileage". Even Hybrids. A lot depends on conditions (temp, elevation changes along your route, wind, driving habits, etc), and it depends on the fuel blend you use. California has 14 different blends, and the one(s) used where I live get 10-15% less mileage due to additives put in to improve air quality.

If you are looking at moding a car....

1. Star with removing weight. Strip out everything you can short of safety equipment. The lighter you make the car the more efficient it will be.

2. Lose weight (if you have any to lose...see #1)

3. Over inflate your tires. +10psi may cause them to wear faster, but you should see an increase in mpg.

4. Drive like a grandma. - You burn the most fuel when you get on the gas to accelerate. Grandma may be slow, but she is sipping fuel.

5. Research Hypermiling (http://en.wikipedia.org/wiki/Hypermiling)
 

Uhtrinity

Platinum Member
Dec 21, 2003
2,251
197
106
Originally posted by: zerocool84
I would never recommend anyone to buy a hybrid. It takes at least 5+yrs for the average person to recoup the extra cost they spent on something like a Prius when they could have gotten something comparably equipped that still got good mpg. It's not like you can even get one for a good price either. They are insanely priced. Just get something like a Civic, Focus, or the like and put the money into something else.

The thing is that you don't even say what type of driving you do or how long you usually keep cars or plan on keeping your next one?

I bought my Insight used for $6,400 over 2 years ago and don't regret it at all. To date it has saved me over $500 a year in fuel cost, the first year it saved me closer to $800 due to the gas spike. As far as reliability, the car is superb.

My parents bought a 2008 Prius over a year ago and also love it. So far they are getting 55mpg mixed vs 20 mpg mixed for the previous vehicle.

Some people will buy a fast car and pay a premium, others want a high mpg car, it's all a matter of personal preference. As of today hybrids rule the mpg market.
 

krunchykrome

Lifer
Dec 28, 2003
13,413
1
0
Originally posted by: zerocool84
I would never recommend anyone to buy a hybrid. It takes at least 5+yrs for the average person to recoup the extra cost they spent on something like a Prius when they could have gotten something comparably equipped that still got good mpg. It's not like you can even get one for a good price either. They are insanely priced. Just get something like a Civic, Focus, or the like and put the money into something else.

The thing is that you don't even say what type of driving you do or how long you usually keep cars or plan on keeping your next one?

Exactly; you could buy a non-hyrbrid that gets exceptional mpg for a lot less. Savings on gas should never be a factor when it comes to purchasing a hybrid, because essentially, there are none. Now, if you want to be green and all of that, then fine- who can argue with your preferences/beliefs.
 

Uhtrinity

Platinum Member
Dec 21, 2003
2,251
197
106
Originally posted by: SearchMaster
What's your motivation exactly? If it's just saving money, just buy the cheapest car you can find that averages 30+ MPG and you'll come out ahead in the long run. There's just about no way to recoup your initial investment in a new Prius/Cruze/TDI/Fiesta/whatever versus a 3 year old Civic/Corolla/Focus/whatever unless you drive ridiculous numbers of miles every year.

It sounds like you're probably more interested in just tinkering with the car to maximize mileage. There's a guy here (Uhtrinity) with an older Insight who is getting like 80+ MPG through battery additions, etc. and is adding (or has added) plug-in capabilities to it. It seems like a hybrid would be better for this type of tinkering than a non-hybrid.

Even un modded 70 mpg mixed it obtainable. The extra battery capacity and plugin charging help more for stop and go driving, and trips that include mountain passes. This weekend I went to Jackson Hole and went over Teton Pass. The car has enough battery capacity to get 45mpg going up one side and then charge plus be in fuel cut going down the other side. Average was over 80mpgs for that stretch. The whole trip netted 70mpg in cold weather which is not optimal for the Insights lean burn.
 

MiataNC

Platinum Member
Dec 5, 2007
2,215
1
81
Originally posted by: Uhtrinity
As of today hybrids rule the mpg market.

A base model Civic (non-hybrid) will give every hybrid on the market a run for its money (beating the SUVs and crossovers), and save the owner $5K+ or more on the initial purchase.

 

Zenmervolt

Elite member
Oct 22, 2000
24,512
21
81
Originally posted by: Uhtrinity
Some people will buy a fast car and pay a premium, others want a high mpg car, it's all a matter of personal preference. As of today hybrids rule the mpg market.

Unless you count Diesels.

ZV
 

Pliablemoose

Lifer
Oct 11, 1999
25,195
0
56
I can't in good conscience recommend a VW TDI.

A Honda Civic will provide you with a platform to mod until the end of time
 

Uhtrinity

Platinum Member
Dec 21, 2003
2,251
197
106
Originally posted by: Zenmervolt
Originally posted by: Uhtrinity
Some people will buy a fast car and pay a premium, others want a high mpg car, it's all a matter of personal preference. As of today hybrids rule the mpg market.

Unless you count Diesels.

ZV

Ok, but not for the US market. The closest are the VW TDI's, but they have been plagued by reliability issues. Btw, the only hybrids I see as worthwhile are the Insight 1 and 2, the Prius, and rounding out the bottom the Civic Hybrid. For SUV's the Escape hybrid, but it now has non hybrid competition from the equinox.
 

LTC8K6

Lifer
Mar 10, 2004
28,520
1,575
126
The new Insight seems to be right in your range on price and mileage.

I know it got bad reviews, but maybe you could test drive one?
 

PhoKingGuy

Diamond Member
Nov 15, 2007
4,689
0
76
Originally posted by: Uhtrinity
Originally posted by: Zenmervolt
Originally posted by: Uhtrinity
Some people will buy a fast car and pay a premium, others want a high mpg car, it's all a matter of personal preference. As of today hybrids rule the mpg market.

Unless you count Diesels.

ZV

Ok, but not for the US market. The closest are the VW TDI's, but they have been plagued by reliability issues. Btw, the only hybrids I see as worthwhile are the Insight 1 and 2, the Prius, and rounding out the bottom the Civic Hybrid. For SUV's the Escape hybrid, but it now has non hybrid competition from the equinox.

Which are? The TDI engine is ridiculously reliable and holds its resale value well to boot. If you're talking about the DSG BS thats going on its not the TDI itself but rather that specific transmission.
 

kornphlake

Golden Member
Dec 30, 2003
1,567
9
81
I'll skip the hybrid vs traditional debate. As far as modding your saturn to get more efficiency I doubt you'd be able to make any significant gains using expensive and difficult to find aftermarket parts. An intake and exhaust will give a marginal increase in fuel mileage, the slight boost in horsepower and change in engine growl may affect you psychologically and net worse gas mileage. Despite what anybody else may say, Detroit engineers do a good job of tuning the econobox engines to balance power, economy and reliability, if you try to improve one of these aspects you are guaranteed to negatively impact one of the others, most likely reliability. In my book if you're decreasing the reliability of a vehicle by tuning or modification, it can not be considered a financial decision.

Unfortunately the 2.2l platform just isn't the ultimate for fuel economy, especially with an automatic behind it. There used to be a website, I can't remember it now, where people would post the top fuel economy numbers for their, often heavily modified, vehicles. Back in '07 when I last remember glancing at the site, none of the top 10 vehicles had engines larger than 2.0, the highest MPG vehicle was a Geo Metro with a 1.0L, 3 cyl engine. The owner had several peculiar driving habits like coasting in neutral with the engine of between stop signs to net something like 85mpg. Many of the vehicles listed were project cars, not intended for daily driving and not driven as daily drivers for the MPG competition. If you're dead set on owning a fuel saving vehicle I think you'll have fewer headaches and more money in your pocket buying an early 90's vehicle that could get 35 mpg from the factory.

The only reasonable upgrade to your Saturn may be swapping the tyranny out for a manual, but that may not be very feasible on an Ion, I know for the S-series it's fairly straightforward, but the S-series is an oddity in the GM family. You could do a few things, depending on your driving needs, like changing tire sizes (which affects the odometer and makes it difficult to calculate MPG) to get a different final drive ratio. Then there are the ridiculous approaches that don't give significant gains but severely limit the utility of your vehicle like putting tape over the seams between body panels to improve aerodynamics and enter/exit the vehicle through the windows, remove the AC since you're never going to use it anyway, get rid of the power steering pump while your at it, don't carry a spare tire or jack an AAA card weighs nothing in comparison, speakers are heavy so you've got to take them out, learn to whistle if you like music while you drive since it's illegal to drive with headphones in every state I've lived in. You should remove the heavy seats, without air conditioning and all the whistling nobody is going to want to ride with you anyway. At this point you've absolutely destroyed the resale value of your vehicle so you might as well start removing the glass from the windows, to be legal you have to have a windshield, the other windows can be replaced with a thin plastic film, I don't think you'd need the heavy oil in the struts because you won't be going fast enough to notice bumps anyway so drain 'em. I'm pretty sure the rear bumper is not there for aerodynamics, it's just cosmetic so yank that off along with the license plate frames. Boeing found that they could save hundreds of pounds on the weight of a 747 by polishing the aluminum rather than painting it , might as well sand all the paint off your car, it's got to save a couple pounds. At this point you've modded your otherwise decent vehicle into a piece of crap anyone would be embarrassed to drive.

If the quest for MPG is purely a hobby, go ahead and dump money into modifications or a new car, but it sounds like your after some financial return. Run the numbers yourself, assume you could buy a new car and get 100mpg, how much do you actually spend on gas each month and how much would you be saving after making a car payment? You'd have to have a very small loan to break even, likewise if you dump even a few thousand dollars in parts and labor to upgrade your current vehicle it will take a long time to save enough money on gas to make the cost financially acceptable. By the numbers the best solution for anyone who doesn't need a new car is to keep what they have paid for, drive and maintain the vehicle until the repair costs exceed the monthly payment on a new car, my best guess is that you're still several years away from the point where you'll benefit from the cost of a new car, with gas prices where they are today, the car would be worn out before the upgrades would pay for themselves.
 

sindows

Golden Member
Dec 11, 2005
1,193
0
0
Keep car, spend money on gas

That's the cheapest and most environmentally friendly way to do this.
 

exdeath

Lifer
Jan 29, 2004
13,679
10
81
Just get an old CRX from the 1980's and get 60 mpg, problem solved.

The Prius and all the hybrid stuff is just hype and nonsense.

Manual will result in worse mileage for most people btw. Most of the time an automatic is running with a locked up converter anyway, and the other times it's keeping revs down and shifting more conservatively than the average person will with a manual.
 

DrMrLordX

Lifer
Apr 27, 2000
21,813
11,167
136
Originally posted by: Turin39789
how many miles do you generally drive per year?

It varies. I'm putting a lot of miles up now that I have a contract for one paper route and regularly sub a second route to save my DM's ass (district manager, not dungeon master . . . alas) on a regular basis and make some extra cashshsh.

The paper route alone is going to put over 14k miles on both my car and my wife's car if we keep this up. Not sure how much mileage I'm going to put on the car now that I have a different day job and now that my wife is slowly but surely warming up to the idea of taking the Ion out on family outings/road trips/etc. versus her PT Cruiser, but I'm going to guesstimate maybe another 10k+ from "other usage" on the Ion.

Originally posted by: SearchMaster
What's your motivation exactly?.

Numerous reasons really, but the most rational reason (if you can call it that) is to have a vehicle that will continue to function effectively in the event of future absurd gasoline prices, gasoline shortages/rationing, and other potential madness. It wasn't too long ago that we had some shortages at pumps thanks to hurricanes disrupting the refining/distribution networks that feed gasoline to much of the South, and even outside of that, $4+ gasoline was just disturbing.

Call me a pessimist, but I see future shortages as being a potential problem.

Plus, having a high mpg vehicle would be pretty cool.

Originally posted by: MiataNC
Anything you drive with a payment is costing you money that could be better spent on whatever additional gas your paid off car is using. If your current car gets decent mileage (@20city/@25hwy or better) you will save a LOT of money keeping what you have.

Few cars get "advertised mileage". Even Hybrids. A lot depends on conditions (temp, elevation changes along your route, wind, driving habits, etc), and it depends on the fuel blend you use. California has 14 different blends, and the one(s) used where I live get 10-15% less mileage due to additives put in to improve air quality.

Yeah, I know. I am hesitant to get a new car just for the fuel savings alone, especially since so many of the fuel-sippers come at a ridiculous price premium. The only real reason that I'm even considering new cars is the possibility of tinkering with them to make them do interesting things. Messing with a low-displacement engine with forced induction could be fascinating for a variety of reasons, and factory turbos are probably going to be more reliable than something from the aftermarket.

Still, that's a boatload of money.

1. Star with removing weight. Strip out everything you can short of safety equipment. The lighter you make the car the more efficient it will be.

100% with you on that one. I'm not pulling the AC though (wife would kill me)

2. Lose weight (if you have any to lose...see #1)

I already border on anorexic, so . . . no

3. Over inflate your tires. +10psi may cause them to wear faster, but you should see an increase in mpg.

I tried that on my Ion, and it didn't seem to help much.

4. Drive like a grandma. - You burn the most fuel when you get on the gas to accelerate. Grandma may be slow, but she is sipping fuel.

Interestingly enough, I've found that my Ion burns the least fuel per mile when I let it run in the rpm range where it is most efficient, which seems to be 2k-3.5k (and if I get it into 5th gear so the torque converter can lock). So yeah, slow ramp-ups help but if I sit too low in the power band, mileage actually suffers a wee bit.


I've done that, and have incorporated a few hypermiling tricks into my driving, though hypermiling with an auto isn't all that it's cracked up to be. I even found some LRR tires that would fit the Ion (Bridgestone B381s) but dammit if they aren't expensive.

Originally posted by: Uhtrinity

I bought my Insight used for $6,400 over 2 years ago and don't regret it at all. To date it has saved me over $500 a year in fuel cost, the first year it saved me closer to $800 due to the gas spike. As far as reliability, the car is superb.

Wow, I was under the impression that Insights were going for a lot more than that. Not sure how many there are available around here, but I'm thinking I could get an old Civic more easily than an Insight.

Still the Insight with the 1.3L TDI engine in it is bad-ass.

Originally posted by: Pliablemoose
I can't in good conscience recommend a VW TDI.

A Honda Civic will provide you with a platform to mod until the end of time

I was thinking the same thing. Only thing that interested me in the TDI is the small engine with a factory turbo. Adding a small turbo to an old Civic should be relatively easy with some help but still . . .

Originally posted by: Skoorb
OP post is too short, need more details.

Needs more cowbell.

Originally posted by: LTC8K6
The new Insight seems to be right in your range on price and mileage.

I know it got bad reviews, but maybe you could test drive one?

I would probably consider one, but I hadn't really been paying attention to the new Insight. Call me crazy but CVTs sort of scare me (I must be biased by the horrendous CVTs that Saturn had in the Ion Coupes). And the base MSRP ($20k) still isn't all that exciting.

Originally posted by: kornphlake
I'll skip the hybrid vs traditional debate. As far as modding your saturn to get more efficiency I doubt you'd be able to make any significant gains using expensive and difficult to find aftermarket parts.

I generally agree, I just happen to really like the car. The idea of modding it for further fuel economy is not entirely rational. In fact, modding Saturns at all is just damned difficult and expensive compared to other vehicles at the same price point.

Unfortunately the 2.2l platform just isn't the ultimate for fuel economy, especially with an automatic behind it.

Again, correct. The 2.2L would have to be de-tuned a good bit, and . . .

The only reasonable upgrade to your Saturn may be swapping the tyranny out for a manual, but that may not be very feasible on an Ion, I know for the S-series it's fairly straightforward, but the S-series is an oddity in the GM family.

Tranny swaps have been done on Ions before, so it can be done. Ecotecs were (and still are) in so many GM cars that there are plenty of options, too. It's not exaxtly straightforward from what I've seen, but it can be done. However, having a shop do it and buying a rebuilt tranny + other parts would, as I understand it, run $3k minimum, and that doesn't count the expense of trying to get someone to mod the final drive on an F40 MT2 to something lower than 3.55 and messing with/replacing the ECU. Still, it would be possible to get taller gears and reduce weight in the engine compartment with a tranny swap. The stock AF23 is fairly heavy.

You could do a few things, depending on your driving needs, like changing tire sizes (which affects the odometer and makes it difficult to calculate MPG) to get a different final drive ratio.

Been there and done that inadvertently with my old Chevy Celebrity Eurosport when nobody had snow tires the proper size when I was in Bozeman, MT. All I can say about that is, "yuck".

Then there are the ridiculous approaches . . .

Nah. I consider that to be cheating. Of course some would consider my Ion to be so stripped-down to be undrivable as it is, but blame GM for that one. Manual windows and door locks don't bother me, but apparently, I am in the minority there.

If the quest for MPG is purely a hobby, go ahead and dump money into modifications or a new car, but it sounds like your after some financial return.

It's not so much financial return . . . it's just that the econobox of the future is getting really effing expensive, and I'm wondering if I couldn't do better restoring/modding an older econobox while saving money in the process (by spending less on the vehicle and then less on gas in the future). I know I'm going to have to buy something new eventually, preferably to render myself immune to gasoline supply disruptions, so . . .

Run the numbers yourself, assume you could buy a new car and get 100mpg

I don't think I can assume that. Were I capable of getting 100mpg with a new car, I would have gone after the Ansari X-Prize.

By the numbers the best solution for anyone who doesn't need a new car is to keep what they have paid for, drive and maintain the vehicle until the repair costs exceed the monthly payment on a new car, my best guess is that you're still several years away from the point where you'll benefit from the cost of a new car, with gas prices where they are today, the car would be worn out before the upgrades would pay for themselves.

Gas prices aren't going to stay what they are today. We may even see rationing at some point in the future, at least for limited periods of time. Once the dollar ceases to be the international currency of trade for petroleum, things are going to get pretty bad. Maybe not catastrophically bad, but $2.20/gallon (about what I'm paying now) ain't gonna last.

Originally posted by: exdeath
Just get an old CRX from the 1980's and get 60 mpg, problem solved.

I would consider that more seriously were the majority of CRXs out there not ruined by ricers. Granted, if a restoration is in order, that might not be a problem . ..

Manual will result in worse mileage for most people btw. Most of the time an automatic is running with a locked up converter anyway, and the other times it's keeping revs down and shifting more conservatively than the average person will with a manual.

You'd be surprised how easy it is to get an Ion to rev to 6500 rpm. Not that I'd do that on a regular basis, noooo . . .

But your point still stands. A manual is only as useful for fuel economy as the driver allows it to be.
 

fleabag

Banned
Oct 1, 2007
2,450
1
0
Originally posted by: DrMrLordX

3. Over inflate your tires. +10psi may cause them to wear faster, but you should see an increase in mpg.

I tried that on my Ion, and it didn't seem to help much.

4. Drive like a grandma. - You burn the most fuel when you get on the gas to accelerate. Grandma may be slow, but she is sipping fuel.

Interestingly enough, I've found that my Ion burns the least fuel per mile when I let it run in the rpm range where it is most efficient, which seems to be 2k-3.5k (and if I get it into 5th gear so the torque converter can lock). So yeah, slow ramp-ups help but if I sit too low in the power band, mileage actually suffers a wee bit.

Bold: See that's the problem, you keep talking about all the things you've done and how you understand hypermiling yet I haven't seen one single statistic come out of you. You haven't even told us what kind of MPG you're getting so how can we believe you when you say that bolded nonsense? How about this for another gem:
Originally posted by: DrMrLordX
Pros: I own it, so I wouldn't have to put up any cash for the base car (and its fully-paid too). It also weights 2650 pounds wet and has a coefficient of drag of .32, which isn't too bad in either department. Not incredible, but not bad. There mere fact that it gets so much better fuel economy on the highway at speeds up to 75 mph (faster than that and fuel economy starts to drop off) seems to be an indicator that drag isn't what's holding the car back from better fuel economy.

Again, more nonsense. Coefficient of drag is most certainly bringing down your mileage, but the problem is how you drive, the way you drive has clearly distorted things so greatly that doing certain behaviors that normally would result in worse mileage are actually resulting in better mileage. Do you actually keep tabs of your mileage or are you just guessing/estimating?
 

Uhtrinity

Platinum Member
Dec 21, 2003
2,251
197
106
Originally posted by: DrMrLordX

Originally posted by: Uhtrinity

I bought my Insight used for $6,400 over 2 years ago and don't regret it at all. To date it has saved me over $500 a year in fuel cost, the first year it saved me closer to $800 due to the gas spike. As far as reliability, the car is superb.

Wow, I was under the impression that Insights were going for a lot more than that. Not sure how many there are available around here, but I'm thinking I could get an old Civic more easily than an Insight.

Still the Insight with the 1.3L TDI engine in it is bad-ass.
They aren't easy to find, but far from impossible. If you are interested in finding one start out with Autotrader or check listings on Insight Central.net. Ebay Insight prices are higher than market value. It isn't uncommon for someone to fly half way across the country to pick one up then drive back. But I would make sure you absolutely want one. They have their quirks and are of course 2 seaters. But nothing else currently available can touch them in raw mpg performance.

The people doing the tdi transplants are quoting $7,000 for engine, adapters, etc, which is more than I would want to pay updating the car. I would be more inclined to do a pure ev mod later.

edit: and I am talking about manual 5 speed gen 1 Insights that were made from 2000 - 2006 of which only 15,000 were ever made. This is the light weight aluminum 2 seater. Then gen 2 version is more closely related to the Civic hybrid.
 

DrMrLordX

Lifer
Apr 27, 2000
21,813
11,167
136
Originally posted by: fleabag

Bold: See that's the problem, you keep talking about all the things you've done and how you understand hypermiling yet I haven't seen one single statistic come out of you. You haven't even told us what kind of MPG you're getting so how can we believe you when you say that bolded nonsense?

Eh? I already listed my general mpg numbers above, which apparently you chose not to read:

I usually keep cars until they commit suicide (which is what my last car, a Mercury Tracer, essentially did) or until the cost of maintenance outweighs a monthly car payment. Usually. My Ion has served me well, and would probably last another 3-4 years if I treat it nicely, but I'm not sure how much longer I want to be married to its 20 uphill/27 city/30 mixed/34-38 highway fuel economy. For most people, that's pretty good, but I want something better than that. That desire, in and of itself, is not 100% rational, but I really don't want to be over a barrel if/when the gas prices go up again.

So, to summarize, I get about 20 mpg if all I do is run up a mountainside, deliver newspapers, and then go back home. It's a lot of stop-and-start driving, but even if I coast through large portions of the route, mileage doesn't get much better. I rarely break 2k rpm while doing this unless I'm short on time and start revving the engine hard. And, well, then there's the downhill but my foot stays off the gas so rpms don't matter much there.

On the highway, I can get about 38 mpg if I dog it at 60 mph (I got 40 once but I haven't been able to reproduce that number). I get around 35 mpg at 70 mph, 35 at 75 mph, and 34 at 80-85 mph (all sustained). In fact I turned in 34 mpg from Chattanooga, TN to Blacksburg, Va both northbound and southbound with a sustained speed of around 80 mph (it was mostly 85, with a few jumps to 90 and some dips to 70-75 as traffic required).

Physics dictates that drag at those speeds is a major factor, but the engine was dealing with it rather nicely. You tell me why that is, if it has nothing to do with increased efficiency within a particular part of the power band? Maybe if I did an mpg test on a dyno I could get a better picture of how the engine behaves at different rpms but I'm not interested in wasting the money on that.

I'm sure awesome aero would make things better, but it would also help if the engine could use a lot less fuel at low revs/idle. Good aero won't help mpg much below 40 mph because drag just isn't a major factor at those speeds, and to be honest, that's the application where I'd like to improve fuel economy the most. Would I like to jump from 38 to 50+ mpg highway? Sure! Would I like to jump from 20 mpg to 35+ on my route? Doubly so.

Again, more nonsense. Coefficient of drag is most certainly bringing down your mileage, but the problem is how you drive, the way you drive has clearly distorted things so greatly that doing certain behaviors that normally would result in worse mileage are actually resulting in better mileage. Do you actually keep tabs of your mileage or are you just guessing/estimating?

About the only thing which I said was nonsensical was that I get worse mpg above 75, which in reality, I don't by much (1 mpg lost, oh noes). I can motor along at around 30-40 mph with periodic stops and get maybe 27 mpg (or much worse on the paper route), or do 75 mph sustained (no stops) and turn in 35 or so. Drag isn't the biggest problem. Regular stops and starts are often the problem. In fact even if I cut down on starts and stops, just staying in low gears and dogging it still doesn't turn in very good mileage on this car. It wants to be in 5th gear with the TC locked at 2k rpm minimum, which is where it does the best.

Again, reduced CoD could improve my highway mpg but that isn't my #1 concern. The 2.2L engine sucks up too much fuel at low rpms/low speeds no matter how casually I accelerate.

Originally posted by: Uhtrinity

They aren't easy to find, but far from impossible. If you are interested in finding one start out with Autotrader or check listings on Insight Central.net. Ebay Insight prices are higher than market value. It isn't uncommon for someone to fly half way across the country to pick one up then drive back. But I would make sure you absolutely want one. They have their quirks and are of course 2 seaters. But nothing else currently available can touch them in raw mpg performance.

The people doing the tdi transplants are quoting $7,000 for engine, adapters, etc, which is more than I would want to pay updating the car. I would be more inclined to do a pure ev mod later.

edit: and I am talking about manual 5 speed gen 1 Insights that were made from 2000 - 2006 of which only 15,000 were ever made. This is the light weight aluminum 2 seater. Then gen 2 version is more closely related to the Civic hybrid.

Hmm, $7k is a bit much for an engine swap, especially if that doesn't include labor. Still worth looking into though (albeit not necessarily with the TDI engine swap). The fact that they are 2-seaters might also tear it for me but whateva. That guy with the aero-modded 90 mpg Civic was quoting 49 mpg mixed for his '92 Civic CX so other options obviously exist. Thanks for the tip nevertheless.
 
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