Just FYI, if you're planning to refurbish your own pack, doing forced recalibrations and using regen/assist on its ailing cells will further damage the weak ones. (More of them may need to be replaced.)
Having said that, I wouldn't hesitate to recommend to any ecomodding type person to buy an Insight with a dead pack, and not bother replacing/refurbishing it. Just use the car as a non-hybrid. As long as the DC-DC converter works to keep the 12v system happy, you can drive it without any of the other IMA functions active and still achieve stellar fuel economy.
I actually see no real reason to refurbish my pack and bring IMA back online, aside from sheer curiosity about the project itself and then getting to play with the hybrid functionality.
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