2000 Insight - TLC and ecomodding build

[Magician]

so... I want to ask. Hypermiling a Gen 1 Insight will easily get over 70mpg? I ask because I'm successfully in the mid 60's in my VX and am considering buying a G1 Insight. Will I be able to easily beat my VX numbers using similar driving techniques?

[Natalya]

Get a 5MT if you want to go for ultimate MPG. Most of these cars aren't going to be up to spec when you buy them. You'll need to make sure it's got the RE92's, good indexed plugs, clean EGR, 0W-20 oil, and the stock underbody aero panels. Once the car is up to spec, the last thing is the hybrid battery. I've never had a good battery and I've been able to get tanks above 70. I think having a good one will let you go even higher.

[Ecky]

If the car is well-maintained, simply driving in a straight line at 50-55 will net 100mpg. They're a lot lighter than a VX, and have regenerative braking and auto-stop, so they're more forgiving in city environments too. Even your average driver will usually still get 60+ tanks so long as it's not all stop and go.

[Ecky]

Brief update:

Lately I've had so little time that I've given up on driving slowly - I find myself doing 65 on the highway when the speed limit allows it, rather than my usual 50, on the few trips I make out of town lately. When the car is empty I can still get 75+ mpg at that speed, but I'm usually hauling something.

My roommate drives my car more frequently than I do, as I've agreed to let him use it now and then and he's less willing to walk or bike than I am. An electric bike has replaced it for most of my around-town trips, while he often uses it to run to the corner store. He has a moped but it's only running as frequently as not. I feel ok about this - harmony at home is worth more than a few bad tanks.

I rebuilt my trailer, and I'm now getting the car prepped for winter, as it seems the first day of fall has hit - it was in the 40's last night, and hasn't been over 70 today.

The accumulated salt damage over the last 2 winters:










The 800F paint I used before seems not to have survived the temperature of the cat in places, but did a fair job of protecting it. The bolts on the side that is more exposed to salt were completely ruined. One of the 10mm bolts came out using a 9mm socket, while the other I needed to cut and use a crescent wrench to remove. One of the studs in the motor's head came out with the nut. The long flange bolts at the bottom which hold the springs are near ruined too - one of them had its threads mostly dissolved by salt. So, I've re-treated what could be saved with naval jelly, recoated it with higher temp paint (2000F this time), and ordered new bolts all around.

[Ecky]

Finally ordered a set of Scott's rear spring replacements. Took about an hour to install in icy rain - 50 minutes for getting the car jacked up, tools as needed, and the first side finished, then 10 for the second. It's a pain that the Insight doesn't have a front or rear mid jack point.

Initial impression: this really is how the car should have shipped from the factory. I'd say the front is still a hair more firm than the rear with the new springs, which isn't bad, but I guess I was expecting it to stiffen up more than it did. It's more like, just on the soft side of "just right". I could probably go a hair stiffer. Body roll is reduced tremendously and since the rear still isn't as firm as the front, it didn't noticeably add any harshness over small irregularities.

Pic is of the old springs, the new ones look about the same, just a tiny bit thicker and less dirty.

[Daox]

Who is Scott?

[Ecky]

Over on InsightCentral, Scott goes by KLR3CYL and has a website, killer3cylinder.com. He sells (among other things) Daewoo Matiz springs which fit the Insight's rear axle and have a higher spring rate. I had him cut approximately 1/3 of a coil before shipping so ride height would be almost exactly the same as stock, despite stiffer springs.

Contact - Killer3cylinder

Rear springs - Insight Central: Honda Insight Forum

He also has premade hitches which fit the Insight, replacement aluminum underbody panels, and a turbo kit.

[Daox]

Interesting! Im not on IC enough it seems. I didn't know about that. New rear springs does sound nice. Though I think I need new shocks too.

[Ecky]

There are aftermarket shocks for sale on the forums too. I believe they're adjustable. I'm not sure if I'd go with those or stock if mine needed replacement.

[Natalya]

Did you ever end up replacing the mosfets or diodes inside the DC/DC?