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.

forced charging
 

You really need to do the clutch switch mod to take control over when the hybrid functions (ie forced charging) are active. Save charging for when it isn't going to hit your MPG. A switch in parallel with the clutch switch is the trick.

When I have the money, first is the SCii, then clutch & brake controllers, the last two being installed with my kill switch and holster.

I would suggest a fan indicator light. I remember someone saying that his car got better mileage even with his fan always on, but you should at least know if it is.

The SCii will show temp, I just need to learn the best operating range. I don't mind the fan being on as long as fan on is still more efficient than a cold and/or parachuting engine bay.

It's pretty obvious when lean burning, especially the transitions- I would like to know how far from/to lean burn I am. I haven't searched yet, but I will need to see if there is anything I can do to zero out lean burn and tell me how close I am to leaving/entering.

The evening did not include any modifications, rather eBaying it up to get some extra change for the SCii, brake & clutch & kill switch wiring.

Subscribed

So I was inspired by a thread for autobahn, or some special mirrors. Well, Wal Mart had 2.99 Towing/RV mirrors. SO, here we go!

This is my mirror.

https://lh5.googleusercontent.com/-F...o/DSC_7594.JPG

I held the unit up to it, and traced on the back the outline of the mirror. Then, I estimated the depth of the perimeter and completed the outline.

https://lh4.googleusercontent.com/-u...o/DSC_7592.JPG

Then, a razor blade to cut it along the lines, and pull just that off when it gets attached.

https://lh6.googleusercontent.com/-c...o/DSC_7593.JPG

The rear.

https://lh3.googleusercontent.com/-N...o/DSC_7595.JPG

What it looks like from the drivers seat.

https://lh6.googleusercontent.com/-i...o/DSC_7596.JPG

Front view.

https://lh5.googleusercontent.com/-t...o/DSC_7602.JPG


This is where my driver internal mirror will go.

https://lh5.googleusercontent.com/-2...o/DSC_7597.JPG

Say goodbye!

https://lh4.googleusercontent.com/-k...o/DSC_7598.JPG

https://lh4.googleusercontent.com/-s...o/DSC_7599.JPG

The drivers side is here, for now.

https://lh3.googleusercontent.com/-D...o/DSC_7600.JPG

https://lh4.googleusercontent.com/-G...o/DSC_7601.JPG

And this is where we're at.

https://lh6.googleusercontent.com/-G...o/DSC_7605.JPG

https://lh5.googleusercontent.com/-W...o/DSC_7607.JPG

https://lh5.googleusercontent.com/-h...o/DSC_7609.JPG

Interior door, not reinstalling this speaker.

https://lh4.googleusercontent.com/-n...o/DSC_7612.JPG

This is the mirror I recommend.

https://lh4.googleusercontent.com/-U...o/DSC_7613.JPG

https://lh4.googleusercontent.com/-Q...o/DSC_7614.JPG


I did not want to start the driver side until the passenger was done with success. If I screwed it up, I could live with a damaged/broken passenger door, NOT a drivers door. Now that it was a great success, I will set up where the mirror goes, and when it is all good, the old mirror will be replaced. To be honest, I never used them- they are all crooked and goofy. It's just too easy (and habit) to turn my head and look before. BUT, these mirrors are pretty decent and have a HUGE view, it shows the entire rear of the vehicle, the left, right, and behind- it's a huge vision area and pretty sweet. Wal Mart.com usually has free shipping for site to store if your local doesn't carry these (I have only seen these at one Wal Mart, in Strongsville, Ohio).

Current Plan
 

Current Plan: Complete driver mirror by end of the week. Within next two weeks, complete Honda dealership inspection, and after the inspection, the underbody will be completed. When I get to pulling the UG out of the Mustang, I may just check the codes myself, but I still want to make sure the underbody looks good.

After that, I will make a rear plate to come out of the rear, to keep the air above and below separate. I may put a plate on the rear, and eventually it will be a boattail, but one step at a time.

1. Driver interior mirror install.
2. Driver exterior mirror removal.
3. Honda inspection.
4. Underbody.
5. Rear flat plate.

Driver mirror is off, mirror on left dash is in place. This morning (or yesterday, maybe) I found the mirror I installed on my rearview on my floor! So today I changed that plan. Rather than making it sticky just for the base (plastic) of the mirror, I cut that part out, to the sticky would be on the window. Depending on how it goes, I may have to use a different adhesive, as this might not hold well.

Nikon was charging, so poor images from my RW Defy lol. The camera isn't a strong point.

https://mail-attachment.googleuserco...bcFJI&sadssc=1

https://mail-attachment.googleuserco...P47mWMJANAGPME

https://mail-attachment.googleuserco...8jAF1G-DcH5hxM

And finally, I have driven 159.6 miles without using 5% of my fuel. Sounds like a good tank! Seriously, though, it is becoming a bit frustrating, this fuel tank. Over filling, and poor tank representation. But it's only been one tank, we'll see. It may have just been that pump doing it.

https://mail-attachment.googleuserco...DVTOGuy9G5_WwY

No pics for me. :(

I'll try to upload a picture tomorrow of my setup. I use the same exact mirror. What you do is pop out the walmart mirror from the base. Drill a hole through the center of the plastic piece. Get a 1 1/4" pipe clamp? Bolt one end of the clamp to the mirror, bolt the other end of the clamp to the stock bolts (underneath the triangular mirror cover that you have to remove) that hold in the window run channel.

The drivers side interior mirror view is fantastic. Equal if not better than the stock outside mirrors. The passenger side interior is "ok," not as great.

There's a guy that uses a wide angle rear view mirror. It's about $20, but it's really professional and gives a great view out the passenger side.

BTW, what state do you live in? Some states are a bit iffy on mirrors.

How practical is the 1st gen insight? If all things equal would you consider a Prius over the insight for the practical rear seat for people/ storage+trunk.

I see the insight as a great A to B car but lacking for storage or as a people mover.

How useful is the hatch space on the insight?

I am located in Ohio.

There are only two seats, so as a people mover, it's not great. But the hatch is has a crazy amount of space, and if you have drill or something, then one can even use the front seat.

Very practical for me, but only a two seater.

this works well for your rear view mirror.

K Source 13.75" x 21.5" Wide Angle Clamp-on Mirror | Product Details | Pep Boys

It's what i've been using on my Del sol and now my STI. Once mounted, I slightly angle the mirror towards the passenger side so i have a wider field of view for my passenger side blind spont.

then supplement with a driver side interior bubble mirror like you already have planned.

It's not planned, it's done! And that is pretty pricey, the mirrors I found were only 2.99 each. But it does look nifty, and the bubble design works great for showing everything. Field of vision is huge!

subscribed..

Ultarc, can you repost the pics from post #18, I can't seem to see them.

They are showing for me, I will retry (unless others know what to do).

On the topic of overfilling and weird mileage for the Insight, I am approaching a record breaking attempt.

At 284.6 miles, I still had 20 bars. At ~330, I dropped down to 18. Two bars for 330 miles? Sounds good to me!

Seriously, though, this may get annoying. Thinking now about how I want to add my wind deflector to pass the air over the wipers, as interior/exterior mirrors are completed. Rear wiper delete is also a must.

yes do it! its very easy and I have never regretted it. also pull the wiper motor, also easy and fill the hole with a " kitchen sink hole filler", and paint it with plasti dip. if you need detailed instructions let me know.

I was going to search it out (thinking about completing it Sunday when I redo my drivers mirror), but I would appreciate your view on it! If it's posted here, others can also use it. (I usually search here, then IC, then the www.)

So I FINALLY checked the codes with my UG. P1456, and P1163.

P1456 on IC net.

I believe it is from running the tank so low. Will now be filling up at around a quarter tank left, at least shooting for that. I will make sure I fill up by 1-2 bars, at the very latest.

P1163 on IC net.

This suggests the EGR valve, so I may have an actual issue with the EGRv. I cleared them, and will see how it works out. I may be learning how to clean my EGRv soon!

Are those other images working?

That's interesting that low fuel would cause a CEL. I have had the gas cap loose code before though. Good luck with that valve! :p

I still can't see the pics, not sure about anybody else. Can you add them as an attachment? Maybe the code isn't working for me for some reason. Or a link to the photo host site?

This is the reference I will be using.

http://ecomodder.com/forum/showthrea...tml#post159596

Getting started!

looks good. pulling the gray trim off requires some strategy at times, obviously make sure you pull it straight out toward the front of the car. also here is a link to the sink hole cover. its basically this but you can get it in white plastic and it comes with a gasket and sturdier mounting system, Shop Danco Metal Sink Hole Cover at Lowes.com
P.S. the plastic one also has too long of a mounting base so it has to be cut a little shorter for the trim plastic to go back on. but i really do recommend the plastic one.

Deleted the rear antenna. I couldn't figure out how to safely remove the metal, so I Plasti dipped it.

Also, I started the final side mirror covers. Waiting for Rust - O - Leum to cure, then Plasti dip, then insulation and putting it all in place,

Did you delete the antennae base, or just the mast? The base appears to be oval, not sure what could be used as plug to that?

Just the antenna. The metal base is still in, being a seal and just sticking up. I do think it is pretty close to a circle, just not totally flat.

Edit:

By antenna, I meant wiper.

1. Done, 2nd time the charm? We'll see in the morning.
2. Been done, but now the inside filled with window Great Foam, and outside cavity w/ GF. This is covered w/ rubberized polycarbonate.
3. Saturday, 0800-1400.
4. After 3.
5. Started development! What was originally going to be used as a boattail/kammback for the Mustang is now going on the Insight as a flat rear panel(who am I kidding, this is the base for the boattail).

Basic checklist:
Upper grille block
Lower ""
Driver exterior mirror delete
Passenger ""
Rear wiper delete

New plan:
1. Rear flat panel
2. Honda Inspection
3. Underbody
4. Partial air dam
5. Side skirts

In the think tank: Grooving underbody to direct air straight back, Prius diffuser, decreasing hood/wind screen angle. Thinking of underbody as all aluminum, brain tsunami on directing air straight back & side skirt design.

Images to follow in the coming days. Just filled up the Mustang (about 50-100 miles early to get summer blend), saw just over 40.

Edit:
Tank was actually 39.55, updated.

Great job!

1-1. 2nd times the charm!
1-2. Images will be uploaded in this post.
1-3. Saturday, 0800-1400
1-4. After 3.
1-5. Is in progress, and pretty effective.

2-1. Done!

For the side mirrors, I explained the process. Guts removed, interior taped off (to stop over filling/squishing out), then GS and the part being fully attached. The same with the outside.

https://lh4.googleusercontent.com/-i...o/DSC_7757.JPG

https://lh4.googleusercontent.com/-2...o/DSC_7758.JPG

https://lh3.googleusercontent.com/-m...o/DSC_7759.JPG

https://lh6.googleusercontent.com/-9...o/DSC_7760.JPG

But, how does one zip tie after the foam dries? Simple- foam it up with the zip tie properly in place, and every so often gently move it, so it does not become permanent. A little force after it dries keeps the foam good, but the tie moves.

https://lh6.googleusercontent.com/-1...o/DSC_7761.JPG

https://lh5.googleusercontent.com/-z...o/DSC_7762.JPG

https://lh4.googleusercontent.com/-q...o/DSC_7763.JPG

After the outside piece is in place, zip ties ran through, one can fill it with foam, then tighten it up and get your final pieces in the right spot.

https://lh5.googleusercontent.com/-E...o/DSC_7764.JPG

https://lh5.googleusercontent.com/-o...o/DSC_7765.JPG

Rear Panel

I used a bike rack to make the main platform. Set it to be as flat as possible. Then, a decent sized polycarbonate chunk was cut to fit perfect, and secured down.

https://lh3.googleusercontent.com/-w...o/DSC_7766.JPG

https://lh5.googleusercontent.com/-Y...o/DSC_7767.JPG

https://lh5.googleusercontent.com/-g...o/DSC_7768.JPG

https://lh3.googleusercontent.com/-B...o/DSC_7769.JPG

Side view

https://lh5.googleusercontent.com/-x...o/DSC_7770.JPG

The main rear portion before cutting

https://lh5.googleusercontent.com/-B...o/DSC_7771.JPG

Attached (kind of)

https://lh3.googleusercontent.com/-g...o/DSC_7772.JPG

It's the same length as Metro's Boat Tail, based off of this post (31 inches from edge of bumper): http://ecomodder.com/forum/showthrea...tml#post361057

https://lh4.googleusercontent.com/-R...o/DSC_7773.JPG

Rear views

https://lh4.googleusercontent.com/-q...o/DSC_7775.JPG

https://lh5.googleusercontent.com/-8...o/DSC_7777.JPG

Side views

https://lh6.googleusercontent.com/-5...o/DSC_7779.JPG

https://lh5.googleusercontent.com/-7...o/DSC_7782.JPG

Current Sideview (Mirror)

https://lh5.googleusercontent.com/-M...o/DSC_7783.JPG

https://lh6.googleusercontent.com/-f...o/DSC_7784.JPG

Current Sideview (Quarter Panel back)

https://lh4.googleusercontent.com/-v...o/DSC_7786.JPG

https://lh6.googleusercontent.com/-v...o/DSC_7785.JPG

There is DEFINITELY a difference. Acceleration has not changed, but coasts seem to go on FOREVER. I also thought I was lean burning poorly, 65-70 via Iguage, but then I felt the LB shift...and was cruising w/ LB at 105-110.

It may be in my head, but it feels like the rear end is looser. As if a parachute is no longer catching the air. My roommate and I test drove it and as I was coasting she asked what was wrong with my engine, and I had to explain I wasn't even in gear... :)

Before this modification, I traveled 749.0 miles on 9.20 gallons. Looking forward to seeing this performance over the tank!