Quote:
Originally Posted by i2k
having been hit by a semi in one of my first-gens, i can tell you first hand: a) you don't want to mess with the structure at all. Honda is not kidding when they say that even the spare tire is an integral part of the space frame, and that the passenger cage is as safe if not safer than NASCAR specs, as long as the frame is fully intact and the spare tire is torqued in place.
is your goal to carry more stuff, carry more people, or to be able to "camp" in such a vehicle? if more stuff, it is easy enough to put together a lightweight trailer using one of those aerodynamic rooftop carriers for SUVs. if more people - just one more? are they small? we've done 200+ mile road trips with a smaller adult in the hatch area, she finds it comfortable. finally, if to camp /carry stuff - get a metro. what i miss most about my metros was the one i had just the driver's seat in, and the rest was a flat platform. i could carry quite a bit of gear AND sleep in it. i don't miss the rust, the the lower fuel economy, the noise, and the lack of AC.
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/\ THIS. as well as the post about the TDI wagon.
Why not go the TDI route? With the money and time spent into engineering an unsafe stratched insight, you could probably spend that much on a mkiv TDI wagon that has a good safety rating and ample space in the rear. (I say moderately because once you cut the body you jeopardize ALL crash integrity without a full rollcage IMHO). The only way you can maintain the safety (assuming the added weight doesn't compromise your crumple zones) is to do a bang-up job strengthening the chassis with extended welds into the existing unibody, especially around the door frame. Otherwise in an accident, the original parts will split off your welded extension and fold out like a trapezoid, squishing you like a tomato.
With a TDI You've got a car engineered to be (really) safe, you can probably lay down in the back, and get good MPG with the diesel, without breaking a sweat. I just imagine a cut and welded car like that Geo folding quite literally like a TIN CAN in ANY sort of frontal collision. If you DO use a full rollcage, connected to a tube-frame extension, I see substantial weight gains and cabin intrusion of the cage. So you've saved your internal organs but your head will smack steel when you get hit or roll over. Game over unless you drive with a helmet.
In general you'll have a LOT invested for a mostly functional car that may have tracking issues, poor sound deadening, difficult climate control, and quite a few engineering issues to overcome, all besides the safety aspect (do you want a door on this extension....etc..).
Get a jetta, enjoy the creature comforts, mod the shiznit out of it. You'll spend less time with any VW gremlins it can will throw at you, compared to the challenges of reengineering the insight... assuming you finish without going broke, and it works.
OH and the TDI will pull a camping trailer too...try that with an extended insight.
I saw this yesterday:
To conclude, unless you're way more capable than the average human at building vehicles, I hope nobody ever rides in your stretched creation without knowing exactly how safe it *may* be.
Also, get better brakes if you intend to get carried away filling your new car with camping crap.
If you know what you're doing (I hesitate to think so if you're here asking for tips), I wish you good luck and hope you make a cool creation!
p.s. - totally serious get a TDI.
