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Lightweight fiero 101: 2300 pound curb weight is my goal by sunofjustice
Started on: 11-25-2010 04:43 PM
Replies: 445 (29067 views)
Last post by: Francis T on 08-02-2017 08:11 AM
sunofjustice
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Report this Post11-30-2012 07:08 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post




5 lb tail light, yikes!!!!

Lets jenny craige it,baby.......











Rear tail light mod comparo.

With the tailight mod, removed metal taillight brackets, tail light bolts, bulbs(3)....

Removed ......................2 lbs / 12. 7 oz
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Report this Post11-30-2012 07:24 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Aesthetically, I was'nt that happy with it.

Then I thought about just ditching the whole thing,
use horizontal "slats" ( think testarossa rear) with 69 firebird LED tail lights.

This, coupled with the trunk perimeter lightening openings,
would allow additional engine heat to vent OVER the rear bumper as well as underneath.

Cost, and the "lightbright" look made me reconsider for now,
then I remembered the trick I used to make my mom's 91 sunbird look
like it WAS'NT hit with an ugly stick before I sold it.






Decent.

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Toontown Fiero
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Report this Post11-30-2012 07:37 PM Click Here to See the Profile for Toontown FieroSend a Private Message to Toontown FieroEdit/Delete MessageReply w/QuoteDirect Link to This Post
Wow 2100 pounds!
You have any shots of the interior now? Have you been driving this car much? How's it handle?
I'm finding this thread interesting, keep it up!
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sunofjustice
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Report this Post11-30-2012 07:42 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post
Finally got around to putting the kibosh on that crappy,
choke-fest of a factory Y-pipe.

I started with the heat shield. (The new exhaust WONT be wrapping
around the engine like the factory had it.)





Roughly 2 lbs of heatsheild, with some old, nasty heat insulation. yum.

[This message has been edited by sunofjustice (edited 11-30-2012).]

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sunofjustice
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Report this Post11-30-2012 07:56 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Toontownfiero,

It is a blast! The car still needs a 4 wheel alignment,
so I drive it sparingly.

But, on the way back from the weigh in, I could'nt resist from
doing a few impromptu burn outs. 0- 60 mph was EFFORTLESS.
( Six seconds maybe.......) I can damn near take a street corner at 40 mph.


I love it!

[This message has been edited by sunofjustice (edited 11-30-2012).]

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sunofjustice
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Report this Post11-30-2012 08:17 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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I have quasi-completed the interior (version 2.0 maybe).

I'll have to post something tomorrow.

It's not bad, but I'm having headaches trying to find glue
that has enough moxy to unite my choices of foam, with
my choice of vinyl.
( It is NOT unusual for me to glue one or two pieces,
wait a few hours before joining them together. Just to see the vinyl
try to "lift-off" slightly, or cause a wrinkle or two.

(Some uber spray adhesives were $15. a can, and the vinyl
STILL tried to lift off!???)


Maybe I should have some pieces professionally SEWN down.

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Report this Post11-30-2012 08:53 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Was excavating on the front end and found more than
some rusty bits and spare sheet metal.



Coolant leak. Not huge, but a leak non the less. So, I tried this........



worked pretty good, still dry as a bone.

Went back to remove frame tabs........









Close to a pound each. (12 .7 oz.)
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Report this Post11-30-2012 09:16 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Radiator support was toast, so I used a piece of aluminum barstock
to replace it. Had a pic, changed my mind about it, and deleted it.
Sorry. To be honest, just did'nt feel like getting bitched at about it.

Removing the old rad support .............3 lbs

Removed misc. metal from air dam area........1 lb / 7 oz.

Whilst pondering how the heck to reconnect the rubber/ plastic (?)
radiator air dam, another epihany hit me...........

What if you move the radiator air dam to the front fascia???


This would help with ADDING down force, by preventing lift
which the stock front-end generates a 100 lbs of. Hmm.

Lets try it...........




Some light cutting with metal shears, some sanding.............







My car has a goatee like me. LOL
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sunofjustice
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Report this Post11-30-2012 09:21 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Did'nt drive it until the sides of the front spoiler were done,
but I thought about it quite often. This is getting exciting!
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Report this Post11-30-2012 09:40 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Decided to have FUNCTIONAL front brake vents,

Tried lightening holes...........changed mind.






test fit.....



Paint.......



otherside........





Removed 2 lbs of metal for BOTH sides. Aluminum vents are about 3 oz. each.

Plus, they should control any road debris from "shot-gunning"
through my future hood vents.
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Report this Post11-30-2012 09:47 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Introducing future ALUMINUM hood. Nuff said.







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Report this Post11-30-2012 09:59 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Whole hood weighs 9 lbs..........

Metal cost $150. ( for 2024 alum. sheet)

Metal cost $20. (aluminum bar stock for frame, thanks LOWES)

Heavy duty, harden bolts $20. ( Thanks ACE hardware)


The last two estimates were fairly ROUGH, but very close.

Total cost $ 190. Doing it yourself ..............PRICELESS.
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Report this Post11-30-2012 10:26 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Taped up window , using "cheater" method to remove it.
Besides, the window has huge spider cracks in it,
and the "ford special tool" will be fun to use.








Started out as a five minutes, its a wrap "fun"...............
then progressed to a "why are'nt I done?" hour. Doh!



Victory.......





30 lbs of winshield.
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sunofjustice

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New window was gonna be a $350. Percy's speedglass special,
but since this is a FIRST attempt.....I'd rather try installing an el cheapo
poly carb window . ( If you consider $150. bones "cheap" that is.)

Cant find pics for lexan, (figures) will have to post final result of window.

Old window ................30 lbs

New poly carb (makrolon)...........10 lbs

Removed...........................20 lbs
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Report this Post12-01-2012 10:45 AM Click Here to See the Profile for BlacktreeClick Here to visit Blacktree's HomePageSend a Private Message to BlacktreeEdit/Delete MessageReply w/QuoteDirect Link to This Post
WOOHOO! SoJ is back!

Just out of curiosity, where did you get the makrolon sheet for the rear window? I've been looking around, and nobody seems to have sheets wide enough to span the whole window (unless I buy a 4x8 foot sheet, which would be really wasteful).
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Report this Post12-01-2012 10:54 AM Click Here to See the Profile for Toontown FieroSend a Private Message to Toontown FieroEdit/Delete MessageReply w/QuoteDirect Link to This Post
How are you going to put the bodylines in the hood? Or are you not worrying about them?
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Report this Post12-01-2012 02:04 PM Click Here to See the Profile for Stubby79Send a Private Message to Stubby79Edit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by Blacktree:

WOOHOO! SoJ is back!


+1!

Been checking in here regularly to see if I missed an update. Glad to see you back, SoJ!

PS: You messed up. You were supposed to get it down to 2300lbs, not 2100!

[This message has been edited by Stubby79 (edited 12-01-2012).]

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sunofjustice
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Report this Post12-01-2012 04:44 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post
Blacktree, great to hear from you too!
I purchased The TINTED makrolon from a local plastics
supplier ( Laird plastics in warren, michigan).
No disrespect, but try your LOCAL phonebook under " plastics ".
Or, if All else fails, Lowes and Home depot sell makrolon as well.
Toontownfiero,
Actually , I was planning on doing a large "rally stripe", or hood applique(?),
that WIDTHWISE would reach exactly to the edges of the two OUTER hood lines.

Sort of like Dodges's 70' AAR cuda, that had a flat black hood theme.
Except, I wanted to do a FLAT RED stripe (cranberry???) to match the rest
of the car. " Ghost stripes" if you will. Who knows, I might still do it.


Stubby 79, Pretty funny! LOL
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sunofjustice
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Report this Post12-01-2012 11:34 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Went to meijers earlier to take some more pix......






Window still needs a weather strip seal, plus window edge repaint.
( Used a pinpoint silicone bead to seal window. Light+waterproof.)



Not perfect, but turned out OK..........
Creation of first poly carb windshield was a rollercoaster of angst/ and fun.
I'm looking forward to the Percy's speed glass, when money / time allows!
(Supposedly, you can scrub it with steel wool and it WONT make a scratch.)
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Report this Post12-02-2012 12:15 AM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post
Here is a peek at interior, version 2.0........







My FINAL interior design requires alot of electrical work
to attain it ( new speedo, move blinkers, idiot lights,
delete more unused wires, get rid of old instr. pod, etc.),
most of which I am not good with.


So, I put that idea on the back burner and used this interior
configuration for now.

I like the vinyl, but the vinyl DOES'NT like the foam.
$15. a can adhesives still keep lifting off. oyvay.

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Report this Post12-02-2012 01:24 AM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Still have to get rid of stock tach, but concerned that ecm
may still be using the signal from it, or using it to complete a circuit.

Equus 5" tach is pretty light for its size, under a pound if i recall.
Equus triple gauges were real lightweights too ( 10 to 11 oz. with gauge cage.).

My old , factory dual gauge pod (without cover,w wire pigtail, plastic bezel
+alum. surround)
was ...........15.7 oz.

Old autometer temp gauge with metal cup was roughly .........1lb.

A-pillar plastic trim, unused boost gauge (was planning to supercharge it),
autometer ELECTRIC fuel gauge with mini junction box, misc. wire, sender etc.
...................3 lbs.

Main dash gauge pod, dash cover, dash surround,+ plastic dash skeloton
....................3 lbs.

Over head lights ..........8.8 oz.

Heatercore ( copper )..................2 lbs.
( Could use an aluminum grand am core, have another idea though.)
Heatercore car length aluminum tubes+ hoses...................2 lbs.
Extra coolant .............roughly 1lb.

Stock rearview mirror......................12. 7 oz.

(Converted panaramic race mirror from a "grabber" type, to a direct
over head bolt on.)

Took someones advice (or was it a heckle?), to ditch steering wheel cover.
Weight removed.....................1 lb.
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sunofjustice
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Report this Post12-02-2012 01:52 AM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post
Some pics of 8 lb exhaust w homemade muffler.
Quasi hidden MSD wires, one wire alt., lightening holes.....






Was planning to redo the 5 ", dual exhaust megs in aluminum,
but changed my mind .
So, I went with a central mounted 3" exhaust instead.
( Much props to Blacktree, yo!)

[This message has been edited by sunofjustice (edited 12-07-2012).]

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sunofjustice
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Report this Post12-02-2012 02:27 AM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Report this Post12-06-2012 03:47 AM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post
Posting some more pix, since I ran out of space on my cheapy digi cam
last time..........



Central mounted exhaust..........




Quasi hidden MSD wires.............

By using the 90 degree sparkplug boots (2 oz. less, EACH ),
I removed almost a full pound in spark plug boots. ( 12 oz.)


Since the wires would have cooked if installed the conventional way,
I routed 'em UNDER the headers with lots of tiny wire seperators.

With the wires routed in this way, they are'nt in a DIRECT heat-path
as they were before.
( As a precaution, the wires near the block are wrapped
with a spare, modified DEI sparkplug boot protector.)
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Report this Post12-06-2012 04:30 AM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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8 lb. exhaust, homemade muffler/ y pipe........









Sort of arbitrary.Crude but effective.
Originally, I had some 5" aluminum tubes
that were going to be for dual exhaust megs,
but they were still too heavy.
And, after factoring in the cost of
an aluminum muffler, y-pipe, V-bands, pipe (alum. VS steel),
custom fabbing, welder DOES'NT like fieros, etc.
I'm possibly looking at $600. worth of work.
Yikes.

So, I thought.......what if the muffler "triples" as a y-pipe, down tube, and muffler?

Total cost: roughly $60. ( plus one and half weeks to assemble. Bolts only.)

[This message has been edited by sunofjustice (edited 12-06-2012).]

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sunofjustice
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Report this Post12-06-2012 05:11 AM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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Due to phobias about headers rusting from heat wrap,
I never FULLY did the entire exhaust.

But, after removing the old THERMAL-TEC wrap (!3 yrs!)
so I could get at the factory y-pipe, I found it was healthy
and solid as a rock.

Maybe the long life ( of the pipes) was from me spraying high heat paint
on it all the time.

http://www.vhtpaint.com/products/flameproof/

Regardless, I like the new DEI TITANIUM wrap.
Seems tough (so far) , fairly light, flexible, and it's affordable.
( Used two and half rolls so far.)
Headers are next.

http://www.designengineerin...t-wrap-lr-technology

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Report this Post12-06-2012 05:54 AM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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One wire alternator............




Bought used alt. ($20.),
returned / exchanged /reclocked used alt.,
STILL no charge, asked a friend for $ to rebuild it.
Friend bought NOS alt. from autozone......($100.)
He ordered it RIGHT, but it had the WRONG pulley,
and needed reclocking too, so I suggested we return it.
Went to Kings auto (VERY cool mom/pop speedshop),
was considering c100(?) alt. UPGRADE, but at this
point anything that had to do with more wiring,
was SERIOUSLY ticking me off

So, I went next door to Marv's electric, and he hooked me up
with this one wire, self exciting alt. ($60.)
The rebuilt alternator charges a full 14 1/4 volts, and works great.
hallejuiah!

[This message has been edited by sunofjustice (edited 12-07-2012).]

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Report this Post12-07-2012 03:35 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post
Forgot to add pics of Rodney Dickman's ALUMINUM
clutch master , clutch slave , replacement hyd. line, and
"diy one-man bleeder kit"........




The parts were top notch, came with clear instructions,
and had helpful install tips.
( The bench bleeder kit, that came with the master, was well appreciated.)
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Report this Post12-07-2012 04:06 PM Click Here to See the Profile for sunofjusticeSend a Private Message to sunofjusticeEdit/Delete MessageReply w/QuoteDirect Link to This Post

sunofjustice

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When I finally finished installing the poly carb window,
that's when the clutch started getting bitchy to get
in gear while running. Great.
Well, It HAS been about two years since I last rebuilt
the master, and slave cylinders.
( MR2 upgrade for slave $7., at advance auto.)

I was going to rebuild the cylinders again, but the opportunity
to upgrade to aluminum was too tempting.
( Two birds with one stone.......brand new, plus LIGHTER.) :thinking:

Here's the old parts........







New master pic, (roughly 1 lb 17oz., could'nt find rest of pix.)



New slave weight was fairly similar.


New parts shaved roughly a pound off. Nice.
Clutch feel is outstanding! I now have a HIGH, PROGRESSIVE clutch engagement.
$200. WELL spent. I love it!

[This message has been edited by sunofjustice (edited 12-07-2012).]

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Report this Post12-08-2012 04:39 PM Click Here to See the Profile for BlacktreeClick Here to visit Blacktree's HomePageSend a Private Message to BlacktreeEdit/Delete MessageReply w/QuoteDirect Link to This Post
I see a rod-end where the stock rear toe link would be. Did you build that yourself, or buy it somewhere? Is it the RCC bumpsteer kit?
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Report this Post12-09-2012 07:53 PM Click Here to See the Profile for mcguiver3Send a Private Message to mcguiver3Edit/Delete MessageReply w/QuoteDirect Link to This Post
anyway to view the pics you guys are posting?
They don't appear in the thread
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Report this Post12-09-2012 10:49 PM Click Here to See the Profile for IXSLR8Send a Private Message to IXSLR8Edit/Delete MessageReply w/QuoteDirect Link to This Post
Yes, that's the RCC bump steer kit. I had the same one on my 87GT.
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Toontown Fiero
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Report this Post12-28-2012 02:07 PM Click Here to See the Profile for Toontown FieroSend a Private Message to Toontown FieroEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by sunofjustice:

Trunk was 18 lbs.

Misc. trunk metal (outer perimeter/ bulk head).......3 lbs

Trunk metal (decklid lock base)............................12.2 oz

Total: 21 lbs / 12.2 oz


Which part of the trunk is 18lbs? I've thought about cutting the trunk and making it more shallow....like putting a flat piece of sheetmetal where there is a flat area already on either side maybe about a foot below the top. I never use the trunk at all but mine is a hobby car. Would make it a lot easier working on the exhaust or the rear side of the engine/tranny without that trunk in the way. And 18lbs is a lot of dead metal riding around back there.
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Report this Post12-28-2012 03:29 PM Click Here to See the Profile for dobeySend a Private Message to dobeyEdit/Delete MessageReply w/QuoteDirect Link to This Post
I don't know if you're intending to keep this car street legal or not, but have you kept track of which things are and aren't legal for street use, that you've swapped to? For example, the switching to lexan of the windshield is almost certainly not DOT legal.

Also, what's the current total weight at?
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Report this Post12-28-2012 03:54 PM Click Here to See the Profile for 2.5Send a Private Message to 2.5Edit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by mcguiver3:

anyway to view the pics you guys are posting?
They don't appear in the thread


They should be, could be your browser, or someother internet prob on your end?
1st rule is always reboot PC
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Report this Post12-28-2012 04:40 PM Click Here to See the Profile for XysterSend a Private Message to XysterEdit/Delete MessageReply w/QuoteDirect Link to This Post
Awesome thread. So much valuable info. + to you.

BTW, why is this not in the construction area? This thread is far to valuable to ever become archived.
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mark1970
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Report this Post12-28-2012 07:39 PM Click Here to See the Profile for mark1970Send a Private Message to mark1970Edit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by pmbrunelle:

The 3.4L aluminium block would be a good place to start.


i agree alum. block, heads, and alum. flywheel and lightweight pressure plate would reduce weight by 200-300lbs...

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Stubby79
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Report this Post12-29-2012 11:27 AM Click Here to See the Profile for Stubby79Send a Private Message to Stubby79Edit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by mark1970:
i agree alum. block, heads, and alum. flywheel and lightweight pressure plate would reduce weight by 200-300lbs...


~100lbs, maybe. 2-300? not likely. The stock V6 weighs ~360lbs. The old buick all alumnium V6 weighs 285lbs. And the only aluminum block I know of for the 60 degree V6 line is from GM racing or some such and is worth more than most well kept Fieros.

You could proably shave 50lbs off with an aluminum head 3400 and an aluminum/chromoly flywheel without breaking the bank.
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Toontown Fiero
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Report this Post04-03-2013 02:45 PM Click Here to See the Profile for Toontown FieroSend a Private Message to Toontown FieroEdit/Delete MessageReply w/QuoteDirect Link to This Post
bumpity bump.....anything new soj?
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mcguiver3
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Report this Post04-03-2013 05:26 PM Click Here to See the Profile for mcguiver3Send a Private Message to mcguiver3Edit/Delete MessageReply w/QuoteDirect Link to This Post
I havent followed this thread for a while now but in reply to the Lexan Windshield.
I just replaced the one in my 88 race car for the second time.
I have a template made from cardboard and buy a piece 32"X 60 from a local distributor.
This last one (3/16") cost me $80
BTW the car is down to 2250#
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