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Old 02-25-2013, 10:12 PM   #1 (permalink)
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Join Date: Nov 2007
Location: 1000 Islands, Ontario, Canada
Posts: 21,238

Blackfly - '98 Geo Metro
Team Metro
Last 3: 70.09 mpg (US)

MPGiata - '90 Mazda Miata
90 day: 52.8 mpg (US)

Winter beater Metro - '00 Chevrolet Metro
90 day: 73.57 mpg (US)

Fancy Metro - '14 Mitsubishi Mirage top spec
90 day: 55.99 mpg (US)
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Making a durable (removable) upper/lower grille block for the UFO: 2000 Honda Insight

It's coming up on 2 years since I got the Insight. I figured it's time to lose the taped-on plastic, and make something a bit more permanent/durable (but also removable). I've taped and re-taped this thing so many times, I've messed up the paint a little bit.

(Photos from: )

Last time I made a permanent block was for the Firefly (Metro). I made a custom vinyl "bra" for that car:

(From: )

Worked well, and is aesthetically fine since the car is black. But I didn't want to put a black bra on the radioactive-snot-green UFO, and finding colour-matching green material seemed unlikely. Also, closing the upper opening wouldn't be easy with material.

I'm inspired in particular by the quality work CigaR007 did on his Echo:

So I'm making this one out of rigid foam insulation.

Actually, this is my 2nd attempt at using foam - I started work on an expandable foam upper block last year, but abandoned it. I've had no luck with the expand-o-foam approach to building mods. Each time I've tried to work with it, it seems too soft, doesn't shape easily, doesn't cure if you put it on too thick, etc. etc. etc.

I got started this evening. Should have some pics tomorrow.

Latest mods test: 15 mods = 15% MPG improvement: A-B test, 2007 Honda Civic 1.8L, 5-speed
Ecodriving test:
Manual vs. automatic transmission MPG showdown: Nissan Micra 1.6L

has launched a forum for the efficient new Mitsubishi Mirage - fuel efficiency info for Geo Metro owners - electric car conversion on a beer budget
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