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Old 10-26-2019, 01:04 PM   #82 (permalink)
Natalya
Engine-Off-Coast
 
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Join Date: Apr 2016
Location: Atlanta
Posts: 564

Red 2000 Insight (2017 through 2019) - '00 Honda Insight 5MT
90 day: 64.72 mpg (US)

Red 2000 Lithium Insight (2020) - '00 Honda Insight LTO
90 day: 71.76 mpg (US)
Thanks: 224
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The biggest problem is finding out how to fit everything in the IPU case and to secure the batteries.

Pic 1:
I cut a hole in the side of the IPU case using an angle grinder. I then zip tied a sliced rubber hose to cover the sharp edge. This was a tight squeeze because of the rubber hose. Cut 1 extra half inch to the right if you can and it will fit great.





Pic 2:
Building brackets for the batteries to rest on was by far the hardest part. This set is imperfect and needs to be modified, but it works for now. I need to get a TIG welder.





Pic 3:
Fitment test with bracket and hole cut in IPU case. Notice the junction board contacts are going to short on the bracket.

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