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Old 09-05-2015, 04:59 PM   #42 (permalink)
RedDevil
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Join Date: Dec 2012
Location: Nieuwegein, the Netherlands
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Red Devil - '11 Honda Insight Elegance
Team Honda
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Anything worth doing...

Picking up where I left yesterday, drills and tools unwilling to cut into the hard iron battery box.

Well I thought I was not that methodical yesterday.
As the saying goes, I should have given it my best shot from the start.
So I got my best drill out and compared all of my steel drill bits to find the best ones.
Took one of those and put it in one of yesterdays hard labored bore dimples.
It sank right through in a second. Huh, what?

Okay then. I have a 22 mm hole to make. Outline that with small drill holes; that saves me a lot of filing away the steel. This should be fun.

Only to find that those nice sharp drill bits get blunt in 3 holes or so. I keep the speed low, but when it stops cutting and I apply more pressure the bit breaks.
I hate this.

Nonetheless, by the end of the day all 3 battery boxes have their holes drilled and the charge connector in place:

The fat wire protectors also protect the charge connector

There is a redundant hole with a rubber grommet.
Maybe I'll wire a small voltmeter through that, or a switch. No more iron cutting for now, for sure!
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2011 Honda Insight + HID, LEDs, tiny PV panel, extra brake pad return springs, neutral wheel alignment, 44/42 PSI (air), PHEV light (inop), tightened wheel nut.
lifetime FE over 0.2 Gmeter or 0.13 Mmile.


For confirmation go to people just like you.
For education go to people unlike yourself.

Last edited by RedDevil; 09-05-2015 at 05:05 PM..
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