Honda Insight Under-body Smoothing Panels (custom belly pan / undertray)

[RobertSmalls]

Originally Posted by 3-Wheeler

I'm kind of waiting for Richard to post some of his pictures before I start posting mine, since he is the first to propose extending the Insight. I consider him the "grand-father" of the Insight project.

Jim.

Thanks for the consideration, but go ahead.

My boat tail is framed in wood and foam, and it's been sitting in the garage like that for six weeks now, waiting to be sanded. I've begun to correct some aesthetic defects at the front of my car that I recently noticed, and when that's done, I'll be free to work at the tail again. If I'm not too busy with electro-mods, that is.

Anyway, this weekend, I'll post some pictures of what I've been up to in my build thread.

I am curious about what methods you're using to keep your tail extension straight and true to the equations you developed. I've been using cardboard templates, but I'm not satisfied that I can align them accurately enough.

[3-Wheeler]

Originally Posted by RobertSmalls

....What do you think about using fiberglass + epoxy without foam for the higher-temperature areas under the car?.....

Hi Robert,

Now that the rear bumper guard is off the car, you can get a better view of just how close the muffler is to the foam panels.

This panel survived a 400 mile run to LaCross and back on a 95°F day. If you look closely, you will notice that there is no softening of the foam at all in this location.

You can also make out the slight curvature of the foam to get more clearance with the muffler, including the bottom side of the panel.



Same picture at a slightly different angle.

No problems with heat even with only an 1" air gap. Fiber glass batting could be used to lower temperatures even more.



Jim.

[Otto]

You are aware of the use of a hotwire for sculpting and cutting foam? Such tools can make short work of much of an undertray application, etc..

[3-Wheeler]

Originally Posted by Otto

You are aware of the use of a hotwire for sculpting and cutting foam? Such tools can make short work of much of an undertray application, etc..

Hi Otto,

Yes, I have seen and used hot wires before...

However, one of my main beefs with this approach is what it does to the surface finish of the foam at the cut area.

It gets crusty/hard from the high heat, and shrinks slightly as well.

Then the area has to be sanded to get rid of the crusty material, and this takes a while since it is harder than the softer material around it.

Also there is the smell of the burning foam when cutting...

I like the much simpler approach of simply cutting with a hacksaw blade or similar.

But for cutting a large area, the hot wire can be handy.

Jim.

[jjackstone]

Also hotwire cutting on foamular gives off toxic fumes. JJ

[Otto]

Originally Posted by jjackstone

Also hotwire cutting on foamular gives off toxic fumes. JJ

Use as low heat setting as possible, and use polystyrene (Styrofoam) rather than urethane foam, the former safe and the latter toxic. Heat deformation should not be a problem--this stuff used extensive for model aircraft wings, which done correctly are not warped or bent from heat, but remain straight.

Foam also an excellent choice for making wheel fairings, etc..

[3-Wheeler]

Originally Posted by Otto

....Foam also an excellent choice for making wheel fairings, etc..

Actually, some day, that's exactly what will be used to streamline the Insight rims for better air flow....

And I need to work out a good way of securing them to the stock rims. I think several drilled and tapped holes will be in order when the time comes...

Jim.

[RobertSmalls]

Originally Posted by 3-Wheeler

Actually, some day, that's exactly what will be used to streamline the Insight rims for better air flow....

And I need to work out a good way of securing them to the stock rims. I think several drilled and tapped holes will be in order when the time comes...

Jim.

Epoxying a fiberglass wheel cover to the center cap works great for me: http://ecomodder.com/forum/showthrea...tml#post173457

[Ecocinqueboy]

Hello,Three Wheeler,

I am very impressed by all the work you have done on your undertray.

1. I was wondering how you allow all the heat from the cooling system,the engine and the exhaust to escape ,especially the cats which run really hot.
2. Is the heat not trapped between the underpan and the underside of the car body?
3 In winter I suppose that it warms the car interior more easily but in summer ,is there not a fire risk?

Ecocinqueboy.

[bobo333]

Wow!

id seen you amazing boat tail build but hadn't realized until now you used the same techniques on the under body too!

amazing attention to detail and persistence.