2000 Insight Build Thread
 

This is the build sheet of my 2000 Honda Insight. The initial thread of the vehicle can be found here.

As of this post, two modifications have been done. Initial upper grille block is of course functional, and I carpeted the hatch.

The grille block. My original is in duct tape, the second version is a primitive flap. Measured the space to cover, then I found the most efficient piece to use. Started making gentle changes, and made it to fit.

Original:

https://lh5.googleusercontent.com/gx...w328-h218-p-no

Current:

https://lh4.googleusercontent.com/kj...w328-h218-p-no

https://lh5.googleusercontent.com/8U...w328-h218-p-no

https://lh3.googleusercontent.com/xl...w328-h218-p-no

https://lh4.googleusercontent.com/fj...w328-h218-p-no

https://lh3.googleusercontent.com/cJ...w328-h218-p-no

The only image I can find of the old rear hatch. It's dirty, worn, and one can see the pull cord for the hidden compartment.

https://lh3.googleusercontent.com/jY...w328-h218-p-no

The new rear hatch. I think it looks good. The mess will be cleaned when I detail the rest of the vehicle. Clean, and covers the rear opening.

https://lh4.googleusercontent.com/5b...w328-h218-p-no

https://lh4.googleusercontent.com/5m...w328-h218-p-no

https://lh3.googleusercontent.com/L9...w328-h218-p-no

Some beginner tips: Measure twice, cut once. Even if you have plenty of materials, you don't want to mess up a design or hard work by missing a point. Double check your work, and be careful.

Cut away from you. It was difficult at first, but seeing how bad one can cut themselves, I started cutting away from myself and it has gotten easier and easier, almost becoming second nature.

Be gentle, and don't rush! Don't let stress, frustration, or fatigue ruin your project. In the past it has caused issues for me, but since, I now take breaks and slow down. I'd rather it take a little longer to make my first draft, then have to redo all my work because I wasn't careful. Stress and fatigue will make you want to get it done faster.

Performance test. Over my 11 mile commute, I reached 65.3 mpg. The test was completed at 20:30, began shortly after 20:00, temperature was ~60 degrees F, cold engine & tires (last trip was completed by 15:30).

Edit 1:
For doing the rear carpeting, one should definitely just remove the rear cover (or even buy a used/ruined one) and use it as an outline to just copy the perimeter. One could definitely save time, and maybe salvage more extra carpet. About 2/3rds through the project, as I laid in the back of the Insight with a razor blade, realized this lol.

Edit 2:
For purchasing an Insight, please utilize this resource: http://ecomodder.com/forum/showthrea...ems-18892.html
I consulted it before I was ready to get one, and when I had decided I needed a second car, I checked it out. Before browsing/getting ready to purchase, it was well read. The first post contains everything in the thread, but it is still worth a read.

Edit 3:
Lower Grille Block 1
Passenger Mirror Delete

Your grille block looks a bit like a moustache :) I like that! :)

Good luck with modding your Insight.

Hey. I plan on trading in my trusty Chevy for something else. 1 of the ideas of course is a high mpg car.

How is the comfort level of the Honda insight? I might be tempted at shopping for one next year, how does insight compare to the geo metro. I feel the metro has more storage space. It would seem 50-65 mpg make them comparable.

I had a basic Honda hatch and the ride was so rough, my body was sore all the time from the ride.

Subscribed.

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93hatch, you're right that a Metro has far more storage. But the Insight is far nicer to drive (refinement, handling).

The Insight in lean burn cruise mode simply blows the Metro out of the water, in terms of mileage. They're in different leagues. My modded Firefly (Metro) can average ~70 mpg (US) on trips where I have a ~45 mph target cruising speed (rural, secondary roads). A modded Insight would be well over 100 MPG in the same conditions.

Lean burn & excellent aerodynamics are a magical combination.

Will follow this with interest, subscribed.

Another lucky Insight owner... congrats.

I would love to do what MetroMPG did, but that would cost money. Right now I am working especially on a budget- eventually it will become better, when I get done with other projects, or have some extra change, it falls off, something along those lines. The original looked good to me, the duct tape. It was hard to even notice from a few feet away (hurray for Silverstone Silver). I am thinking to just rubberize this, and then paint it silver. This design should let the engine breathe more, while the duct tape was a total seal on it.

Metro is definitely the man to speak to on that [question]. Compared to the Mustang, it is a brand new Lazy Boy. One thing that contributed to a super comfy 500 mile ride was not figuring out how to operate the seat, and the gentleman before me enjoyed a relaxed ride. I kept my PPE in my lower back, and it was still comfy- normally I can only last ~40 minutes with the Mustang, let alone 500 miles.

Another point of Insight > Other is the all aluminum body, and the aero based design already. A full underbody, and full wheel skirts will be easier to do on the Insight than the Metro.

Subscribed :thumbup:

Day two of modifications. I want to get the basics done, even if they aren't pretty yet. Today my aero mods were a full lower grille block and sealing the openings between the underbody and edge of the bumper, while interior was temporarily fixing the seat belt.

The seat belt does not need pictures. The belt is twisted, and when the twist is above, the belt does not retract- maybe a safety hazard, definitely annoying. I don't have the tool to remove the bolt, so I removed the lower plastic piece and tucked the twisted part at the bottom, where it will not get in the way of the functioning of the belt.

The lower grille block.

https://lh3.googleusercontent.com/-m...o/DSC_7515.JPG

https://lh6.googleusercontent.com/-A...o/DSC_7516.JPG

https://lh6.googleusercontent.com/-g...o/DSC_7517.JPG

https://lh3.googleusercontent.com/-K...o/DSC_7519.JPG

https://lh3.googleusercontent.com/-h...o/DSC_7520.JPG


Some quick tips;
-When working with corrugated plastic, make the short cuts against the grain, and the long cuts with it. It will help make them (the cuts) smoother, and easier to cut.
-

Closing the gap.
It is small, but it needed to be done. The damage to the skid plates (not aggressive, but if you asked the parking lot curbs, they might say otherwise) is evident. The issue is they were not put on properly, or had issues, and they left a gap that surely was causing extra drag. I taped it like a duct!

https://lh5.googleusercontent.com/-S...o/DSC_7521.JPG

https://lh5.googleusercontent.com/-2...o/DSC_7523.JPG

https://lh6.googleusercontent.com/-Y...o/DSC_7525.JPG

https://lh3.googleusercontent.com/-a...o/DSC_7528.JPG

https://lh4.googleusercontent.com/-i...o/DSC_7529.JPG

The vehicle so far.

https://lh3.googleusercontent.com/-R...o/DSC_7531.JPG

https://lh3.googleusercontent.com/-c...o/DSC_7532.JPG


Tested the route again, and the engine should have been warmer, as the last drive was completed around 17:40. Same setup, ~58 degrees F, left at 19:57, arrived back at 20:25. The original total MPG was 65.0. The total for the first three trips was 63.4 MPG. This trip resulted in 64.3 MPG, a decrease from yesterday.

Although temperature is a bit lower, I believe the issue was recharging. Yesterday I noticed very little other than downshifting and braking- it was charging so little it didn't read. Today it consistently charged most of the way, making it harder to get to speed, and harder to get to and keep lean burn.

It probably won't be an issue this winter, but consider getting a SG or UG so you can monitor intake temps, and more importantly water temp. You don't want your grille block to cause the fan to come on more than normal. And unless the factory gauge is numerical, it isn't precise enough to see 10 or 20 degree movements.