02 G1 Insight with many ecomods- 999.6 mile tank @ 105 MPG

[Baltothewolf]

What moon disks are those? I like that you can still pull the rim/check pressures with it on.

[The donkey CRX]

Here is a list of the current mods that have already been made to this car. I plan on showing pictures and explanations for all of them here. If you have any one you are interested in, let me know, and I will cover it first.

MIMA/PIMA IMA battery control of regen and assist functions of the IMA battery.

Genesis One grid charger. This item and the above one where sold by Mike Dabrowski over on the Insight Central site, but are no longer available. This is the main reason we decided the purchase this particular Insight.

OBD2C&C from 150MPG@gmail.com to monitor IMA SOC, volts and amps.

Wideband O2 senor and gauge

Manual adjustable Warm air intake attached to the catalytic converter.

Manual adjustable Grill block

Bridgestone RE 92 low rolling resistance tires mounted on alloy 14"X4" Insight space saver spare rims. (with vinyl "moon" covers)

100 AH LIPO4 deep cycle battery with DC/DC converter bypass switch.

FAS injector "kill switch" This item was already installed on the car also.

Pre heaters for water(block and circulating thru radiator), oil, and transmission fluid.

Relocated OEM outside air temp sensor from front of grill to top of engine to "spoof" sensor to read higher outside temps. Also added another temp sensor beside this one connected to a gauge to read this temp from the instrument panel.

Relocated the OEM intake air temp senor close to the catalytic converter inside new WAI tube to "spoof" computer into thinking intake temps are higher. Also added another air temp sensor to this one attached to a gauge on the instrument panel.

Extended OEM front belly pan to enclose more of the engine compartment to the rear and sides.

Added all new LED lights including head lights.(did not replace rear brake light bulbs).

Added the following gauges and instruments:

Water temp in upper and lower radiator hoses.

Oil temp and oil pressure with a "sandwich" between the oil filter and oil cooler.

Air temp sensors in front of grill, in engine bay, where the OEM AIT sensor was formally located, inside cabin, and on the LIPO4 battery.

Added a volt, amp, and amp hour meter to the LIPO4 12 volt deep cycle battery.

Added a MPGuino so I can monitor instant and trip to date MPG without the 2 minute delay of the Insight gauge.

Now I have a "see thru" instrument panel

[The donkey CRX]

These are the OEM Insight alloy space saver spare tire rims. They are 14"X 4" and the regular rims are 5 1/2" wide.

If you go to the thread for the 92 Red Mule car " Aeromodded Civic VX 72 MPG" The #1 perma link on page one shows the wheel without any covers and starting with perma link #130 shows how I made the vinyl covers for the rims and also where you can buy the vinyl. This is the same material used to "wrap" entire cars.

Sorry I don't know how to put a link here to make it easier to find.

admin edit: http://ecomodder.com/forum/showthrea...tml#post427797

[cowmeat]

Now I have a "see thru" instrument panel

Holy cow man, that's some hard core instrumentation you have going on there!

It's like one of those station wagons you see with bumper stickers from all the places they have vacationed plastered all over the back, but on the inside of the windshield.

I did happen to notice you're still sporting OEM side view mirrors. Check out Ron Burgundy's page for pics of my tiny aero mirrors, they'd be a perfect fit for your set-up! If you're interested I can pop one of mine off this weekend, send it to Daox for sizing up, and he can start 3D printing housings for the Insight guys. I've been too lazy so far, but your Insight is renewing my interest!

[The donkey CRX]

Thanks for the offer on the mirrors Cowmeat, but when I get the time I want to make some small mirrors that stand out of the airflow of the car with airfoil type stalks. Yours would look much nicer, but I have found that small mirrors that are out away from the body offer me a fuller view to the rear of the car.

[The donkey CRX]

If you read the mods list above you my come to the conclusion that getting more heat into the engine and removing all external loads like regen and 12 volt power drains is the key to getting the engine to stay in Lean Burn almost 100 percent of the time.

This little 3 cylinder engine is extremely efficient when in lean burn, but will not stay there unless the water and oil temps are above 160 degrees and the intake air is above 120 degrees. The computer also seems to need to see outside air above 80 degrees. I think a lot of this is because Honda was trying to keep the NOX as low as possible when the engine is in lean burn.

So I found that by getting to these temps or "spoofing" the sensors to think the temps are this high is one of the main keys to constant lean burn.

I am also grid charging the IMA and the 12 volt LIPO4 battery each night and when I get to the shop in order to take as many outside loads as possible from the engine so it can use all of its limited power to move the car.

I use the MIMA/PIMA IMA system to turn off all regen and assist unless I use the joystick to manually apply it when needing to climb hills without leaving lean burn.

I still have a lot to learn about the most efficient way to get increased MPGs from the Insight, but think I am going in the right direction.

[The donkey CRX]

Here are some pictures of the Warm air intake.





The stainless steel clam shell surrounds the catalytic converter and directs the warm air to the intake. I try to maintain 120 degrees at the intake









The O2 sensor to the left is the one I added so I can be sure of when the engine is in lean burn with the gauge on the dash






2 1/2 " silicone duct carries the warm air to the intake and also draws in fresh air to adjust the temps with the exhaust cut out valve .

[The donkey CRX]

The OEM intake air sensor has been relocated within 8 inches of the catalytic converter inside the 2 1/2" insulated duct. In this position the sensor "sees" between 120 and 170 degrees even if it is too cool for the actual intake to see high enough temps to allow lean burn. The computer doses not seem to mind if the temp is as high as 170 degrees. It must just be looking for temps of at least 110 or 120 degrees. If too high temps become a problem, I will just relocate the sensor father away from the cat.






Here is where I moved the outside air temp sensor that was in front of the grill. Also notice the small silver colored sensor I have attached to it in order fro me to monitor the temp on the dash

[Ecky]

Inspiring.

Removing electrical loads definitely helps. Even very minor draw really shows up when you're shooting for 100+. I'm frequently able to get trips that high, but having to use assist sparingly so as to keep the HV battery up really robs mileage, and I'm not sure that grid charging every night will be healthy. Replacement batteries aren't exactly cheap.

I think it's time I made a proper WAI.

*goes outside to relocate air temperature sensor, and to plug in 12v charger*

[Baltothewolf]

Grid charging packs nightly - is- bad for the pack, it's been proven by the battery gurus at IC that it harms the cells on a long term basis.

There are multiple people who run 180-200F intake temps for MPG in the insight.

Nice mods and cockpit! A writeup on that adjustable grill block would be awesome!