[sandt38]

MetroMPG- Thanks for assembling such an in depth, cohesive account of your experience with the Insight battery rebuild!

I am an automotive technician in central NC who has been rebuilding Prius batteries. My shop, and a friend's shop in Raliegh have been active in training, meetings with battery engineers, electric model users, and other professionals across the country who have stepped outside the "toss a pack in it" box and figured out how to do what most shops will not do... dive into the dreaded hybrid battery pack and rebuild it. We have opted to find our own methodology, equipment, and approach to reconditioning batteries outside of the only other option offered by AR&D, at a $90K pricetag with royalty fees of $150 due for every cycle.

While I have done work on several Honda hybrids I was presented with a 2000 Insight with a bad pack this week. My challenge was to ensure that I could properly manage my cycles to compete with an AR&D rebuild that this customer has had done on his 2 othe Insights.

Your detailed information here, and tear down images made me confident that I can achieve the same success that AR&D did with this gentleman's other reconditions. I am grateful that you took the time to research the pertinent info for experienced reconditioners and put them all into a single, well organized place complete with your end results. I was so impressed that I joined the forum to see what else is offered here (and to subscribe to this thread).

Cheers!
sandt