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Old 09-17-2015, 03:34 PM   #25 (permalink)
The donkey CRX
Master EcoModder
 
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Join Date: Feb 2013
Location: TN
Posts: 300

MULE VX - '92 Honda civic VX
Team Honda
90 day: 92.6 mpg (US)

White 94 VX "Show Car" - '94 Honda Civic VX VX
90 day: 79.92 mpg (US)

The Walrus - '02 Honda Insight base
Gen-1 Insights
90 day: 100.88 mpg (US)
Thanks: 399
Thanked 564 Times in 189 Posts
Adjustable grill block

Here are some pictures of how I constructed the adjustable grill block for the Insight. On the VX's I had almost 6 inches of gap between the grill and the radiator to fit the shutters and the adjustment cable. On the Insight that gap was barely 3 inches. This forced me to redesign how the shutters are actuated by the push pull cable. I had to mount the cable underneath the shutters instead of behind them.












Because the front plastic bumper was so flimsy, I attached the shutters to the bottom of the sturdy aluminum bumper.



The push pull cable is routed under the oil pan to reach the shutters









Both the push pull cables for the WAI and the shutters enter the cabin of the car from a 1 1/4" hole I drilled right next to the exit hole for the drain tube for the A/C evaporator. This access hole was also used to route all of the electrical wires for the sensors and gauges. Sorry, I don't have a picture.
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