When the Insight fan comes on, can you hear it easily? I have yet to hear mine come on, and I run a radiator block, but have it set to 75% right now.
I also monitor the ScanGauge and typically keep it below 197°F or so.
My wife has a Honda Fit, and I can hear her fan come on anytime we are sitting in traffic, and I have not *touched* her car. She knows me too well!!
If the fan makes enough noise, I may try card-boarding over the entire lower bumper opening and see what happens. We're in the 30's outside right now.
Jim.