Originally Posted by Ryan
What are the differences? Other than interior and body.
EDIT: By which I mean what makes the Cobalt a superior vehicle?
1st, crash test ratings. The cobalt and corolla were the only two compact cars to receive and "acceptable" rating on side impact crashes. The cobalt did better in all crash tests than the ion.
The Cobalt is built in a true unibody construction where the steel panels on the outside of the car actually account for some of the structural rigidity.
The ION is bilt on a unibody steel space frame where the outside panels are plastic and can be removed with no effect on structural rigidity.
The Cobalt has more acoustic insulation and makes use of laminated "quiet steel"
The Cobalt is also supposed to have closer fitting body panels.
Lots of little things, like the pad so your keys don't make noise banging against the dash...
Basically GM gathered customer comlaints about the ION, and when designing the cobalt fixed as many of the problems as they could.