2000 Insight Build Thread

[MetroMPG]

Originally Posted by UltArc

Friday, I am building my Fiberglass lower grille block, boat tail, and maybe an upper grille block. I may have to complete my kill switch, also.

All in one day??

Maybe you can find time to broker a Mid-East peace accord while you're working on such a light schedule.

Watching with interest...

[UltArc]

Update, the lower grille block is well on it's way, fiberglass went perfectly, as did the first layer of foam, and the second is in process of curing. I haven't tried removing it with the second set of foam, but it is a perfect fit!

Thanks to HALO automotive parts for the free front bumper to use as my mold, WIKIhow for how to use fiberglass, and RedPoint for inspiring me to do it. I am not in love with the material, and can't help but think of everything I can do with it.

I reviewed the upper grille block, and decided not to start cutting and messing with it yet because I'd have to remove my current blocks- so lower needs to be completed, then upper can be done.

I didn't do my kill switch or my IMA on/off switch, because I am lazy, but I did replace my map holder net.

The wooden frame for the boat tail is built, and on the Insight. I am nervous about the nails and frame coming undone with the vibration, so I will not be nailing anymore, rather zip tieing the PC on to it, and then fiberglassing the frame together with the FG, and FGing the edges of the PC.

[tpotts]

Photo of tail frame, how long? What is the rear dimension? Square or rectangle? Thanks Tom

[pgfpro]

WOW!!!

You made some great progress!!! Can't wait to see all the hard work.

[UltArc]

Alright, time for the update!

First off, the next gen lower grille block. Wax paper down, with little stickies to hold it in place, followed by fiberglass, dry down, then resin/hardener painted over it. It is pretty stuck to the wax paper, but that doesn't matter. Great foamed in, two thinner layers, and now it just needs to be designed to look good (or better, I should say).

Images-

My front end, donated from HALO Auto Parts




Wax & FG








Dried



Layer two of GR





Boat tail wooden frame













Current point







As usual, looks don't matter for the original design. Also, I am low on PC, so I have to stretch it out to make it work. Nothing is tight yet, because the other ends still need to be attached. The frame is nailed, then zip tied, then FG around the major joints.

The car is having issues without the battery pack working, but hopefully Honda will have it in within the coming weeks.

[pgfpro]

I'm loving it!!! Nice progress!!!

[UltArc]

Originally Posted by pgfpro

I'm loving it!!! Nice progress!!!

Thank you, a LOT of work to do, still. I am glad I was over ambitious and tried to get a lot done, because the heater I had trying to warm things got it up from 40-42 to low 50s, in a general few feet around it.

So while one thing was settling, I could work on another area. But something is better than nothing, even if it's rough lol

[UltArc]

I got the Insight back today. The 160 mile tank was yielding 56.x mpg, driving up a little over 40 miles has brought the tank average to just short of 60, 59.x.

So, the changes:
Four brand new RE92s on the stock wheels.
One brand new IMA battery.
Honda techs tried to reinstall my boat tail- and smashed my equipment in the hatch, and it is now seriously lodged in. I have tried everything short of a pry bar.

Air looks decent, but I am sure not up to 60 psi. Glad to have her back, and functioning.

[tpotts]

Wish you success in fixing the boat tail. I have covered the front (openings of the baby car except for 4 inch duct. . With a cut
plastic plastic material (like you used on the tail)and duct tape. Will use that form later for making something more permanent. Filled up with Regular non eyth. Have driven in town and in very hilly roads (45 lbs pressure). 73.7mpg with 375 miles. Although it is not my best I think it will continue to go up as the tank gets lighter. Car seems to roll much further. Good luck with reconstruction of tail. Keep us posted, I hope to build one myself. Best Tom

[UltArc]

Old news, new RE92s on the corners, new IMA from Honda.

The new news if the first image:



Nine beautiful pieces of polycarbonate board.

Here is what I did with it:












It already feels smoother while driving. It could be mental, and I could be compensating subconsciously by driving more efficiently. I don't think so, as I was holding 59.x-60.x, but it is slowly climbing, I am now holding 60.3. Beyond this, in a 35 I drive through with a slight incline, I am actually able to hold 35-39 in lean burn, rather than having to pulse to 39 and hold lean burn down to 35, and back up again.

I think it is wicked compared to the original, and eventually I may fiberglass it.