The plan is...
Fit replacement motor. I have found a motor reasonably local with 55,000km on it. The seller and I are close to agreeing on a price, just not yet.
Register it.
Begin “Hyper Miling” mods. Because Australia, I can’t go too far down this path - the big aerodynamic mods they do in the USA would see it defected off the road virtually instantly. And things like removing the rear brakes would make re-registration difficult...
Similarly, adopting the more extreme driving styles they use would see me either un over or involved in a road rage incident within a week, so that will limit me a bit too. Not to mention the police attention that I do not want.
As such, I don’t think that it will properly count as a hypermiler, but I should be able to do enough to achieve my goal.
Breaking the planned mods down into three basic groups:
A) Driveline/suspension/brakes.
1.8 Lancer gearbox. These have a taller diff ratio and a taller 5th gear. I am a little worried that they might be too tall, but am hoping that smaller (lighter) tyres will be able to get it back to where I need. Worst case is that I will use the 1.5 diff ratio with the 1.8 gearset or vice-versa.
Extractors & 2” exhaust to try to improve efficiency.
Running low viscosity oils in both the motor and box.
Wheel size is TBA due to the gearing, but skinny tyres are a given. 155s or 165s . If it ends up with 15s, then I will fit S40 front brakes .
Koni yellows, because I own them.
It will stay this low for aerodynamics, if the rego inspector allows it.
Power steering delete for less drag on the motor.
B ) Weight loss.
Not going to go crazy here, for the sake of comfort and legality. Plus most of my commute is at 100kph so weight loss doesn’t help much there.
The spare tyre will be replaced with a can of puncture sealant, rear wiper will be binned, rear speakers will go to god, etc.
I have a suspicion that the plastic fuel tank from a CH Lancer might fit. If it does and I find one cheap then it can go in too.
C) Aerodynamics.
I am out of my depth here, so the following list is a mix of guesses and ideas that I have found from reading. If anyone knows better, then I am all ears!
Smaller rear view mirrors.
Remove the gutter moulds and stick vinyl over the join between the windscreen and A-pillar, and over the join in the roof.
Tape over the gaps around the headlights and indicators.
Remove the mudflaps.
Make 0.6mm aluminium covers for the fog light indents in the front bumper.
I am also considering (but not ready to commit to):
Flat underfloor. Flat floors definitely work, but are a lot of work and create heat management issues.
Work out a way to cover the gap between the roof and the top of the hatch.
Wheel covers (aka Moon Eyes). This will partly depend on what wheel size I end up with. Aerodynamic wheels from one of the factory cars is the preferred option, as they stand out less.
if I can find a front lip that actually helps stop air getting under the car, then I will fit that. There’s been a plethora of body kits made for these cars, but they were all exercises in bad taste - I haven’t seen anything that even hints at actual aerodynamic improvement.
Make 0.6 aluminium covers to partially block the lower air intake to the radiator. I am comfortable that this will work fine for the radiator/engine, but am not sure if it will hamper the AC.
“Keels” in front of each tyre/wheel.
D ) Other Economy Stuff.
I will fit the largest windscreen banner that is legal, to help keep the sunlight out of the interior and reduce AC use.
LED globes everywhere.
Solar charger for the battery.
I know that these last two sound a bit esoteric, but apparently they make a small-but-noticeable difference in the long term.
E) No Eco-Modding stuff that the car needs/I want to do.
New bushes in the front wishbones.
Better seats. Awful/awkward shaped Mirage floor makes this a mission.
New carpet. Old stuff is just worn out.
Sports steering wheel from the green car.