2000 Insight 5 speed repair & build thread

[elhigh]

Did cleaning up that screen fix your power inconsistency? I'm all agog.

[Daox]

Oooh, XPS foam sounds like a great idea too. Very light weight.

[Daox]

Originally Posted by elhigh

Did cleaning up that screen fix your power inconsistency? I'm all agog.

Sadly, no. Its still doing its same 'ol thing.

[NoD~]

Originally Posted by Daox

Oooh, XPS foam sounds like a great idea too. Very light weight.

I had to use some "wall dog" screws to attach, because drywall screws pulled right out. They are super large threaded screws, can probably get at any big box hardware store. Coroplast stays in place well with them, though.

[Natalya]

Originally Posted by Daox

Mine was fairly plugged up.

It's good you cleaned it, but this is cause for concern. I hate to throw vague stuff at you, but the guy who I bought my G1 Insight from restores G1s and he told me that usually if there's a valve failure or other catastrophic engine failure the VTEC filter also usually had crud in it. I would post on Insight Central and ask them if there's anything else you should be checking out given the amount of crud in there. I checked mine at about 151k miles and like it was pristine, so seeing this is kind of alarming.

[Ecky]

^ That could be related to the herky jerky.

[Daox]

Ive thought for a while that it may be caused by some mechanical slop in timing or something... It seems so many people have replaced so many sensors and it never seems to fully fix the problem.

[Daox]

For those who didn't see in my other thread, I got the actuated grill block installed last week. I'm starting to tweak the program and make sure it is working properly.





Beyond that, I have worked on the upper grill block because what is the use of an actuated grill block if your whole grill isn't blocked?

I based my entire design off what Darin did with his Insight. It looked too nice to go with anything else, and it seemed pretty easy too.

I started by cutting out the rough shape of the opening in cardboard.





Then I traced that on to a piece of foam board. I cut it large so I could taper it all to the contour of the hood and bumper.





Next, I cut a bunch of slits in the back side so it would bend easier. The saw got away from me a couple times and did take some chunks out... no big deal as I'll be adding filler later on.





I taped it to the Insight so it would hold its shape to the contour of the body.







Next, I made a backing piece to hold the contour.







Hot glue was used to bond the two pieces of foam together. I figured it works well for radio control airplanes it should work good here. I do hope there aren't heat and dripping issues. We'll see!





Lastly, I put a coat of bondo on the front. It'll require some more work and a bunch of sanding, but its well on its way to being a pretty and functional piece of the car.

[MetroMPG]

Upper grille block looks very familiar!



I like the hot glue idea as well. I used drywall screws to join the 2 parts.

[Daox]

Haha, yep! Most of my mods should be familiar. I'm really just taking what I like from everyone else who has done things to their Insight and doing the same or very similar thing to mine... Though I do have some special mods planned that will surprise people.