Cobalt spindle and Koni adjustable Coil over Struts

OK we have a lot going on these pics, first of all I wanted to upgrade my axle shaft without having to buy custom ones. I kept breaking axles with my 2.0 turbo engine setup so I looked around and the only direct bolt on solution would be to have some custom ones made up at a cost of about $900.00 to $1500.00. So what I came up with would allow me to use readily available parts from a Chevy Cobalt and a Suzuki Forenza or Chevy Optra. I used Spindles from a Chevy Cobalt and modified my stock control arm to accept the Cobalt ball joint, I cut out the pocket where the stock ball joint and burned in some ¼ inch steel and drilled the control arm with the Cobalt bolt pattern. As you can see in the pictures the Forenza axle shaft is a lot more beefy the spline count is higher making it a stronger shaft

While I was add it I also wanted to upgrade the suspension with some adjustable coilover struts but not much is out there so I used a strut from a Cobalt and put in a Koni adjustable strut cartridge and added a Ground Control coilover kit for a Chevy Cavalier. I will add more detail pics when I start working on the other side of the car.

I definitely want to see more on this project!

I'm considering a forenza 2.0L swap for myself someday, and there is no way I could afford custom axles.

Please include more information on your project and let us know how it turns out. And the pics are great, keep em' coming.

:shock: :shock: i love this kinda stuff, 2 bad my wife wont let me touch the ave, cause i'd drop that thing so fast.

nice write up tho~

it looks like the cv joint os about the same size in both those pictures, is the splines a more common failure point on gms than the cv joint?

if you did all that for the addition of coilovers, there was/is a simpler way:

http://img265.imageshack.us/img265/3138/photobzl.jpg

viewtopic.php?f=12&t=27834

plus the endlink kit:

http://img823.imageshack.us/img823/5879/install5.jpg

What breaks is the inner shaft in the picture below you can see how much bigger the Forenza shaft is than the Aveo stock unit. This modification will also facilitate my next upgrade a LSJ engin and gearbox, I have purchased the engine and transmission and should be coming soon

i see that, the first picture was a little more misleading.

Ok here it is I got my tranny with the LSD and I am waiting on the engine, but in the meanwhile I will show you how I but together my coilover. This upgrade will allow you to run axles from a Forenza and set set you up t do LSJ upgrade.

I used a strut form a Cobalt that I modified and put in a Koni Strut insert and I also cut all of the tabs form the stock strut so everything would work out. The first thing I did was to drill a hole in the strut to drain the oil out I then marked the top of the strut so I could cut the top off I then cut the perch off and I sand blasted the strut to get it ready for welding and painting.

Look at the pic below I will keep them coming as I continue with the project.

Attached you will find a pic of the tranny.

I got the LSJ engine I will post pics and info as the project progresses, I am still working on the suspension. I will start a new post for the install of the LSJ.