[BongoBennie]

I close to finishing up with my swap. 2002 Honda Insight with a 2008 Honda Fit Sport automatic. Goal is good milage (50 would be awesome) In a reliable, cheap to maintain car. I will be running 185/60 or 65/14s, 11" front rotors and Ground control coil overs with Koni Yellows/GAZ adjustable shocks. For a beefy and safe feel. The car will be driven 95% at freeway speed and it is what is most important.

I will also have Hondata Flashpro, Long block and trans will be left stock and I will tune for 87 octane.

3 things will be custom
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1 is the exhaust, I will use mandrel bends and have room for two mufflers/resonators as well as my 'free flow cat'. What size do I run? quiet yet free flowing muffler strategy?

2 Is the header, My father is a header builder (from the 70s) and I have the ability to do what ever I choose within reason. Ports are 1.25"..... Tri-Y? 4into1? stepped?

#3 is the reason for my blues. I need to make a custom intake manifold since the stock one would poke through the hood. The intake runners are 16" stock from plenum to head.
The easiest way for me to deal with this is buy a $500 custom Weapon R Intake manifold and cutting all the bends out, re welding and leaving the runners 4" long.
I can also build a header like intake with a small collector plenum into throttle body and get the runners within 2" of equal but can be 18-20 inches long or mimic the stock Insight 3cyl intake design.

Or I can cut my hood (and move my battery) which I really don't want to do

Im afraid of loosing all my bottom end as it is an automatic. Im hoping that with the tuning ability and a great exhaust system, I can make up for the intake manifold compromise. Im not looking at trying to win any races but do want the car to be as efficient as possible.

Im not for asking anything other than ideas and opinions on this.

If I build a short runner intake, can I build Tq with a long intake tube before throttle?

Im willing to go slightly smaller tire diameter as well (Flashpro allows you to adjust speedometer)


Last thing is if all this is going to be over 5% or less power I think Ill be just fine so thats also a part of my question. does it really matter?