Ive had my Insight since May of 09 and have continued to get more mpg along the way. Since my Enginer plug in kit adapted from a Prius 2 design and heavy use of "EV" mode I have exceeded 100 mpg for a few miles. I can average 80+ on my commute to work and in the mid 60s with combination stop n go and interstate with lots of traffic on i95.
Ive maxed out the converter and want to explore other ways to improve mpg. Below is a quick walk around of my car in its current configuration. I plan on removing the starter and crap under the hood and bumper that is not needed, add an 84 cell prius pack in parallel to the IMA pack and PHEV kit. Add an exhaust for the IMA and PHEV converter. Use a few prius sticks in place of the starter battery. Maybe hack the CVT to force it in the highest ratio and a relay to cut in the injectors like a FAS switch. Since the insight uses 10.8 to 1 compression I am tempted to try a chemical intercooler and or water injection for mroe mpg once warmmed up.
Here is a list of a few of my mods: Enginer 4 kilowatt PHEV, 3000k 35 watt fogs, Eco bulb highs, 4300k 35 watt low all w/relay kits, DRLs/Rear Wiper removed&rear interior gutted, Sony HU W/front speakers, Tanabe nf springs, 35% tint all around, all LED lamp replacement, 09 fit progress rear sway bar, OEM block heater, full gril block, KN Filter, Honda vent visiors, group 51 battery, home made balancer/grid charger, rain gutter ground effects, full upper grill block, Removed un-necessary crap from rear including bumper cover.
I cant post a link to the video.
Its on youtube titled Honda insight current setup under Mspider12's account.