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Discussion Starter #1 (Edited)
Current project:

GM (23282827) Lift Cylinder replacement. Anyone have a good guide to do this? Looks pretty straight forward.
https://www.gmpartsonline.net/oem-parts/gm-lift-cylinder-23282827

Eventually I will upgrade to: https://store.clippercreek.com/index.php?route=product/product&product_id=119&search=lcs-30

...and of course... Michelin Defenders :D (I'm a sucker for French tires)

Past Projects:

GM (23165426) Replaced hood insulation from serious rodent damage. Skill: Very easy. Tools standard.
https://www.gmpartsonline.net/oem-parts/gm-insulator-23165426

GM (20993998) Replaced front deflector with a much lower profile one! Skill: Very very easy. Tools standard.
https://www.gmpartsonline.net/oem-parts/gm-lower-deflector-20993998

GM (20871244) OEM Air Filter replacement. Skill: Very Very easy. Tools standard.
https://www.gmpartsonline.net/oem-parts/gm-air-filter-20871244

GM (55352643) Opel Oil Filter (A/C Delco). Skill: Moderate. Tools standard. (if your a mechanic, you might have to visit the home depot if not)
https://www.gmpartsonline.net/oem-parts/gm-oil-filter-55352643

Nice things to have:

GM (55572186) Oil Filter Adapter (A/C Delco). Have one as a backup. Didn't install. If you've needed to do this, please comment below.
https://www.gmpartsonline.net/oem-parts/gm-oil-filter-adapter-55572186https://www.gmpartsonline.net/oem-parts/gm-oil-filter-adapter-55572186

GM (55568037) Drain plug. Bewarned! Very easy to strip these. Have a few as a backup.
https://www.gmpartsonline.net/oem-parts/gm-drain-plug-55568037

GM (23281030) the charging port itself. Have as a backup.
https://www.gmpartsonline.net/oem-parts/gm-charging-port-23281030

GM (12378390) GM 50/50 Coolant. Battery system and Engine. STOCK UP ON THIS.
http://www.gmpartsdirect.com/oe-gm/12378390

follow this guide http://gm-volt.com/forum/showthread.php?119089-Battery-Coolant-and-other-Fluid-Levels-FAQ&highlight=coolant+guide

Minnesota necessities:

GM (20917118) Worth every penny, provides some additional sound dampening. Didn't like any other aftermarket solution including the overpriced Husky things.
https://www.gmpartsonline.net/oem-parts/gm-cargo-area-mat-premium-all-weather-20917118
GM (19243441) snaps right in!
https://www.gmpartsonline.net/oem-parts/gm-floor-mats-all-weather-and-19243441
Aftermarket EV 120v Charger
https://www.amazon.com/AeroVironment-TurboCord-Dual-Plug-Charger/dp/B00J8O1XQE
Aftermarket 4.0 USB Bluetooth Mod for AUX port
https://www.amazon.com/YETOR-Bluetooth-Receiver-Portable-Compatible/dp/B01G8LP75C/ref=sr_1_12?ie=UTF8&qid=1482347261&sr=8-12&keywords=usb+audio+bluetooth+4.0+dongle

New starter battery from NAPA, the LEGEND of course and 0w30 Mobil 1 Advanced Fuel Economy (Green Cap) because its always on sale :p
 

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Things I"ve replaced

3 engines (2 gen 1, 1 gen 2)

1 high voltage battery contactors (internal to the high volt battery)

many drive motor battery coolant radiators

2 gen 1 oil pan gaskets

1 gen 2 high voltage battery tray (some one drove over a parking lot curb and damaged the battery tray)
 

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Discussion Starter #3
Cool! Thanks for the input! Volt techs are awesome, talking shop with one when I was servicing my Silverado was key in my final decision on the vehicle.

Say, any tips, frustrations, what to lookout for as a DIY tinker? Special tools you recommend? I have a ELM Bluetooth reader with DashCommander for my iPad, MyGreenVolt for my phone, and a ScanGuage I, and ScanGuageII.
 

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Other then the Hybrid system, the car is just like any other car, just stay away from the orange battery cables and you should be good.
 

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Things I"ve replaced

3 engines (2 gen 1, 1 gen 2)

1 high voltage battery contactors (internal to the high volt battery)

many drive motor battery coolant radiators

2 gen 1 oil pan gaskets

1 gen 2 high voltage battery tray (some one drove over a parking lot curb and damaged the battery tray)
Why did the gas engines fail? isn't that rare?
 

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The 2 gen 1 motors failed due to over heating, there was a inline check valve in a small coolant hose that goes from the coolant bottle to the radiator that came apart in both gen 1's. Not sure if the over heat caused the hose failure or if the broken hose caused the over heat.
The gen 2 was just sold and had less then 100 miles, mostly EV miles. I have not taken it apart yet but I think a piston came apart in one cylinder.
 

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Discussion Starter #7
@VoltDan
Which I'm assuming is normal, any GM product line is gonna have a few defective units come off the line. Mishandled in transport, etc. I live near a major rail depot used by Toyota etc to bring in product here. I notice sometimes, depending on the shift, they are not handled gently coming of the BNSF rail transports, I can assure you. Anyone interested in a Rav4 take note. The South St. Paul Depot abuses the hell of out em. I know because I worked there in my youth.

@mpmoore1979
You are in AZ right? Did that have anything to do with the overheating issue? LOL last time I was stranded in Rodeo, NM because I had vaporlock but in my panic I put cold water on my radiator... destroying a Corolla in the process.
 

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The 2 gen 1 motors failed due to over heating, there was a inline check valve in a small coolant hose that goes from the coolant bottle to the radiator that came apart in both gen 1's. Not sure if the over heat caused the hose failure or if the broken hose caused the over heat.
The gen 2 was just sold and had less then 100 miles, mostly EV miles. I have not taken it apart yet but I think a piston came apart in one cylinder.
You would think there would be a recall for that gen 1 issue. Interesting. I guess the good thing is Gen 1 gas engines are dirt cheap!
 
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