Honda Insight Tail Extension Project

[3-Wheeler]

Originally Posted by orange4boy

Great job. The car looks fantastic. Efficiency sure is beautiful!

I'm really looking forward to warmer temps this spring for several reasons:

1) doing some tuft testing with a webcam to ensure the shape is correct

2) adding spats, etc.

3) finish sanding the shape for application of matching red paint.

Jim.

[alohaspirit]

looking forward to it!

[animated_zombie]

Spent the day reading through this! I don't know how I missed it before, but amazing work!

[jime57]

Originally Posted by 3-Wheeler

I'm really looking forward to warmer temps this spring for several reasons:

1) doing some tuft testing with a webcam to ensure the shape is correct

2) adding spats, etc.

3) finish sanding the shape for application of matching red paint.

Jim.

I, for one, am very interested in seeing some tuft testing. I think the top and sides are going to be great. I do wonder about the underneath. You have commented before that your under angle is more than the ideal 4 degrees or so. I'm hoping that the bellypan work you did will allow angles greater than 4 degrees, so that will be very interesting.

Beautiful work. I want to build one so badly, but have so many irons in the fire

[NeilBlanchard]

Hi Jim,

Remind me again what materials you are using for the fiberglass; and where are you buying it?

The more I think about it, I think I need to do a "carved foam plug" approach to building CarBEN EV -- with all the interior spaces hollowed out.

[3-Wheeler]

Originally Posted by NeilBlanchard

Hi Jim,

Remind me again what materials you are using for the fiberglass; and where are you buying it?

The more I think about it, I think I need to do a "carved foam plug" approach to building CarBEN EV -- with all the interior spaces hollowed out.

Hi Neil,

The fiberglass cloth and epoxy resin was purchased from U.S. Composites. I just purchased more of the U.S. Composites resin, but have not used it yet as the outside temperatures are still too cold and we are in the process of adding more insulation in the house attic.

If you can make some of the body shape "straight", you might consider ordering Video 2: "How it's made" by The Arnold Company in Vallejo California. After watching it several times, there is a lot of information in there about working with fiberglass and foam cores.

The craftsmanship of his work is absolutely first class once you see the video. If I redid the tail extension, I could probably save five pounds by using some of his techniques. Highly rated. I purchased the DVD after finishing the tail for the winter.

The tail on the Insight is not "straight" and therefore does not lend itself to hot-wire forming, and thus takes quite a bit more time to form by hand, as you have seen in the pictures.

Best of luck to you in your project. Do you have a rough time-frame to completion?

Jim.

[alohaspirit]

hows the tail coming along?


gonna paint it right?

[3-Wheeler]

Originally Posted by alohaspirit

hows the tail coming along?


gonna paint it right?

Hi,

Still waiting for the temps to go up. All through April we've been either cold 40's or rain.....

And yes, later this spring/summer the tail will be sanded smooth and painted.

Working on adding more insulation in the house attic, cutting soffet vents, and working on bathroom cabinets.

Jim.

[NeilBlanchard]

Jim,

Were you the person who mentioned using Elmer's Glue on fiberglass? Would the waterproof (yellow) Elmer's work? I am concerned about several things; one is the biodegradability of the composite skin. And the very low VOC and cleanup of this glue would be much better than epoxy.

[Varn]

I couldn't agree more about the video from arnold. I have the set, (mine are vhs) and it is quite detailed with overlap on the videos. He talks about design drag and construction tips. Well worth viewing.

My only experience with hot wire was when I had built up a block of foam that I was going to carve in to a streamliner and life intervened a few years later. I needed the insulation for my house. I sliced the 2" boards, glued into a block into about 2/3rds inch boards with a homemade hot wire. I used some stainless steel wire and a 5a battery charger as a power supply.

Originally Posted by 3-Wheeler

Hi Neil,

The fiberglass cloth and epoxy resin was purchased from U.S. Composites. I just purchased more of the U.S. Composites resin, but have not used it yet as the outside temperatures are still too cold and we are in the process of adding more insulation in the house attic.

If you can make some of the body shape "straight", you might consider ordering Video 2: "How it's made" by The Arnold Company in Vallejo California. After watching it several times, there is a lot of information in there about working with fiberglass and foam cores.

The craftsmanship of his work is absolutely first class once you see the video. If I redid the tail extension, I could probably save five pounds by using some of his techniques. Highly rated. I purchased the DVD after finishing the tail for the winter.

The tail on the Insight is not "straight" and therefore does not lend itself to hot-wire forming, and thus takes quite a bit more time to form by hand, as you have seen in the pictures.

Best of luck to you in your project. Do you have a rough time-frame to completion?

Jim.