Feasability of an Electric Insight

[Natalya]

Originally Posted by SH@UN

100% this.

The amount of time and money it'll take to do it, it won't even be close to feasible.

Lots of the stuff people do on here doesn't make any economical sense. Prius Chevy pickup? LED lights? Drive super slow? Objectively none of these are "worth" it, and this of course won't be worth it either. Though I guess you could create a CBA graph showing that this is even less worth it.

Originally Posted by freebeard

The problem with running an electric through a transmission is that the shock load applying full torque is measured in milliseconds instead of microseconds. Shredded clutches, & blown automatics as far as the eye can see. The single-speed drivetrain has 100% torque at zero RPM, OTOH it need double the horsepower rating of a gas engine and big fat wires so they don't melt.

This is the kind of stuff I'm worried about. I worked in a factory where we did aluminum and steel metalworking and I can make mounting brackets or weld steel, but I don't have the capability to machine things like gears or a differential.

The primary issue for me is going to be deciding at which point the new electric drivetrain components end and the stock Insight drivetrain components begin. I need to identify the easiest place to make the switch from one to the other. Thanks for everyone's input on this.

[vskid3]

Originally Posted by Natalya

The primary issue for me is going to be deciding at which point the new electric drivetrain components end and the stock Insight drivetrain components begin. I need to identify the easiest place to make the switch from one to the other. Thanks for everyone's input on this.

I think that will largely depend on what you're sourcing the electric drivetrain components from. If you're using a forklift motor or a standalone motor like a Warp 9, your best bet would be attaching it to the Insight's transmission. If you're using parts from a Leaf or other EV, I think it would be easiest to have the transition at the CV axles (so EV motor and tranny, Insight hubs, custom CV axles to join them).

[rmay635703]

I think in terms of cost alone going direct drive is a waste, you have a transmission, it won't need to shift much and few drives are lighter than an insight transaxle.

http://www.insightcentral.net/forums...a-insight.html

Beyond using a beefier Honda transaxle I really don't understand the XMSN being a talking point, use what you have or pay $$$$ and waste lots of time to re invent the wheel.

Only case where it's not a cost add is if you glider the insight onto another EV body, Smart, Imiev and leaf all look like good choices to glider with Smart being the easiest but also least reliable

Ah well

[freebeard]

InsightCentral.net - Encyclopedia - Honda Insight Aluminum Construction

I don't see the logic in butchering the aluminum monocoque.

[Stubby79]

Originally Posted by Natalya

This is the kind of stuff I'm worried about.

It's all up to the programming in the controller/inverter. Even the "cheap" controllers have what's called "throttle ramp", where it takes a certain amount of time to build up the current (therefore torque) when you apply the throttle.

Better units allow you to change/reprogram said ramp time.

[rmay635703]

Originally Posted by freebeard

InsightCentral.net - Encyclopedia - Honda Insight Aluminum Construction

I don't see the logic in butchering the aluminum monocoque.

Only reason would be to get done or save time

Take a look at the ksight builds on this topic.

A Smart EV cradle would be stand alone and simply need the rear Insight tub modded to set the Insight glider. In place on top

Minimal work and oem

[Daox]

I think the Insight is probably one of the best chassis around for converting to EV simply because of the aerodynamics and weight. I've been looking at the I-MiEVs, and soooooooo wish to rip out its drivetrain and put it in something massively more aerodynamic like the Insight haha.

If you want a good idea of the overall process of how to build the EV, I would suggest watching Ben Nelson's videos on how to build an electric car. It goes through quite a bit of the process.

Electric Car Instructional DVDs

Then, you can figure out the finer details here.


I also know a local guy who is looking to get rid of some GE brand 11" DC series wound motors that are apparently very nice (better quality and durability) than a warp 11 HV at a fraction of the price. This guy is a professional motor tester (works for Helwig Carbon, a brush manufacturer) and knows his stuff.

[SH@UN]

Originally Posted by Natalya

Lots of the stuff people do on here doesn't make any economical sense. Prius Chevy pickup?

I gotta disagree. The old Chevy truck with the Prius drivetrain was totally worth it and then some. That's a project that I know for a fact that he could sell and make a profit.

Plus, the cool factor is way off the charts.

[cRiPpLe_rOoStEr]

Originally Posted by Natalya

LED lights?

LED lights are good, not just due to their lower energy consumption (which would become a valuable asset for an EV) but also their longer lasting compared to halogen lamps.

[samwichse]

I think this question is better researched at DIY Electric Car Forums Site Home

You'll find tons of info about exactly what you're proposing to do.