Got me an Insight...

[NoD~]

I wired up a brake/clutch switch. I used Cat6 copper cabling innards to keep the gauge low (weight and size). I was able to tap the power connectors without splicing, though it's not going to be as reliable. Basically, took the copper off the end and shoved them into the connector's back side and taped them down. Switch is wired up temporarily the way it is, but I like the location. I plan to run the wiring through a hole once I change out the stereo, but this works for now. I also want to make it illuminate properly (I got a lot of rewiring to do inside the switch to make that part work.)



I also started on a template for a wood box to fit in the empty rear passenger side space. I figure I can get an 8" in there sealed and make it sound pretty good.




Another thing I'll be working on is the solar fan project. I did it in my Neon and it made a huge difference. Ecky has done it and done it well, so I'll avoid re-inventing the wheel and just copy some of his design.

In the Neon, I did a custom panel that went to a charge controller that also trickle-charged my 12v battery. I also had a temperature controlled relay that did not turn the fans on until it hit about 80*F in the cabin. I'll be doing the relay and making a custom panel for the Insight, but I don't think I'll try to trickle-charge the battery this go-round (but, we'll see.. tapping into the DC-DC converter is very close, but not sure if I want to deal with a charge controller again).

I have TONS of computer fans laying around, just gotta find the ones that make sense. I'm thinking the Arctic Cooling F12 fans. They do a rated 74CFM at 12v/0.24amp. Pretty efficient fans! So I'd need a solar array of about 6 watts to make it work. Gonna have to measure it out and see what makes sense. Probably do an array with 24+ solar cells in series, maybe 1"x3" cells? We'll see!

[samwichse]

Solar powered venting fans for forced air cooling of Honda Insight

Best write-up I've seen in installing solar fans in an insight.

[cowmeat]

You should have Daox hook you up with one of his 3D printed 3-button shift knobs that incorporate brake, clutch and kill switches. It's pretty convenient having all of them at your fingertips

[NoD~]

cowmeat: Close! I ordered a single button from him. I figure I can always change out to more buttons later, but I really don't want too many buttons on the shift knob. On top of that, I am trying to teach my wife how to drive a manual. Accidental button pushing and game over man, game over. I'm hoping to get the plug-and-play kill as well, so I can have all the little features and not have to cut into the wiring harness... The guy who makes them is out of country, but is to get back to me once he's available to make them again.

samwichse: Awesome link! More ideas, the better.

I went and took some measurements and I'm pretty curious... it seems you can trim an 80mm fan (to be like the IMA battery fan) and get it to sit inside the hole in the aluminum body behind each vent. Seal it up, and it should pull air far better than anything in front of the vents. This would also flush it up some, so it wouldn't push on the vent/carpet. Any reason why this wouldn't work or hasn't been done? (or has it?!)

Also, I can easily put 32x of 1x3 cells in the rear window with little/no view obstruction. I think this is the route I'll go, giving me up to 18v for if I want to trickle charge the 12v when the fans aren't active.

Also, here's a glimpse of some of the madness behind my sub enclosure... I'm still debating fiberglass VS all wood. Fiberglass would give me a better fit with more airspace, but it's messy, stinky, and time consuming. Hmmmm...



One other thing I'd like to ask the Insight community on here: How do you have your rear view mirror positioned? It's basically 1 of 2 ways... full out the angled glass, or half lower glass, half angled glass. Just curious.

[Ecky]

I'm a short person and sit close enough to the mirror that I can typically see out of all of the glass in the back, through the rearview.

[samwichse]

Originally Posted by NoD~

it seems you can trim an 80mm fan (to be like the IMA battery fan) and get it to sit inside the hole in the aluminum body behind each vent. Seal it up, and it should pull air far better than anything in front of the vents. This would also flush it up some, so it wouldn't push on the vent/carpet. Any reason why this wouldn't work or hasn't been done? (or has it?!)[/IMG]

One other thing I'd like to ask the Insight community on here: How do you have your rear view mirror positioned? It's basically 1 of 2 ways... full out the angled glass, or half lower glass, half angled glass. Just curious.

If it works better and hasn't been done, my guess would be because it's more difficult. Sounds like it would work.

[NoD~]

OK, if you plan to put some screws into foam, like XPS, you'll need some meaty screws. I had a feeling the regular screws I put in for the front grill block wouldn't last, and they didn't I used these Wall-Dog screws instead and they bite in there hard.



Also, ordered 40x 1" x 3" solar cells (0.5v and 0.68a each; 0.34w). I'll use 28 of these in series to give me about a 14v, 9.5w system. This should easily power a couple of 80mm fans, but also give me the option to trickle charge the battery (with a small charge controller). Should be an interesting little build.

[samwichse]

Originally Posted by NoD~

One other thing I'd like to ask the Insight community on here: How do you have your rear view mirror positioned? It's basically 1 of 2 ways... full out the angled glass, or half lower glass, half angled glass. Just curious.

Full out the angled glass, but just a hair low so I straighten up slightly and easily see out the low back glass.

Sam

[elhigh]

If getting screws to bite in XPS foam isn't working, install some drywall anchors. They look like super-fat wood screws, the threads are about 1/8" deep. That should hold pretty good.

Better still: set the anchor, back it out and shoot some Gorilla Glue adhesive into the hole, then set the anchor again. Let the glue cure before installing your screws. That should hold VERY well.

[NoD~]

I got tired of the damp seatbelts when it rained (and, Ecky's thread shows this mod as reducing noise in motion), so I got the silicone out and did my best to do some tasteful work.



I have it pretty well hidden deep in the cracks, for the most part. Not very noticeable without looking for it, at least.

I started on the enclosure, but nothing to show quite yet. I settled on doing a hybrid of fiberglass and tradition wood. The sides, front, and top will be wood and bottom and rear being fiberglass. This helps maximize airspace, eases installation, and will give the best fit. I should have at least 0.35 cubic foot in the box after bracing and subwoofer displacement, which is perfect for an 8" sub, sealed.