2000 Insight - TLC and ecomodding build

[Ecky]

After pulling it apart, I decided I'll just swap it for a high efficiency Meanwell unit when my hybrid battery fails. Total cost for a rebuild looked like it would exceed $100 parts and there's a high likelihood I'd break it.

At some point I'm likely to try my hand at a lithium conversion.

[Natalya]

Is the DC/DC something simple enough that it could be replaced by a Meanwell with the stock battery in place?

[Ecky]

I believe it will throw a CEL without some IMA spoofing, but there are off-the-shelf units for ~$30-40 which are much more efficient now, with lower volume, lower cooling needs and similar capacity.

EDIT: When and if I go lithium, I'm tempted to try and reduce the IMA compartment volume and regain some cargo space.

[IamIan]

Originally Posted by Natalya

Is the DC/DC something simple enough that it could be replaced by a Meanwell with the stock battery in place?

https://www.youtube.com/watch?v=vwtJ-cvPjRA

[IamIan]

Originally Posted by Ecky

When and if I go lithium, I'm tempted to try and reduce the IMA compartment volume and regain some cargo space.

If ok with OEM or less energy storage amounts .. I think it would be possible to reduce IMA compartment occupied volume to as little as 1/3 of OEM.

You could regain even more cargo volume if you are also willing to give up the spare tire.

[Ecky]

Originally Posted by IamIan

If ok with OEM or less energy storage amounts .. I think it would be possible to reduce IMA compartment occupied volume to as little as 1/3 of OEM.

You could regain even more cargo volume if you are also willing to give up the spare tire.

On top of that, there's a lot of dead space in the back that's just stuffed with foam.

Sadly my battery is strong and my engine runs well, so it might be a few years before I can justify it.

[IamIan]

Originally Posted by Ecky

On top of that, there's a lot of dead space in the back that's just stuffed with foam.

Sadly my battery is strong and my engine runs well, so it might be a few years before I can justify it.

That just means you have plenty of time to look around .. plan it all out .. get a good deal .. get all the electronic pieces together .. test everything .. and just generally take your time putting it all together .. so then later, the swap in the actual car will be nice smooth and very little car down time.

[Ecky]

I spoke too soon about my battery - 3 days after I posted that, my IMA system shut off. I have reason to believe the MCM (motor control computer) failed, because the IMA light is off and I have a "no communication" CEL. However, rather than replace just the computer and risk another one failing in the same way, I'm planning to buy a cheap pack with failed battery cells, and swap my good ones over.

Right now at idle, the DC-DC converter puts out just enough voltage to keep the car from dying, and shuts off above 4k RPM, which I need to rev to surprisingly often.

I went back and forth on whether I might want to run an ECU fooler and gut the hatch (huge weight reduction, lots of space gained), but the Insight's engine is gutless below 3K RPM without the IMA and the gearing is wrong for driving in an area with a lot of inclines. So, for now, going to fix what's there.

In other news, I have my eye on some lithium cells which I might play around with. The 2011-2013 Hyundai Sonata hybrid had a ~1.5kwh lithium battery, 9 x 5.3Ah 30v subpacks in a series. 5 or 6 of these would result in a 150v or 180v nominal pack, with 800 or 950wh respectively. Internal resistance in LiPo is lower, and charging the pack at home would be reasonable, so long as I can figure out battery management translation.

[Daox]

Interesting crossroads.

When I had the Insight on the road, I primarily drove it without IMA turned on with my clutch switch. I definitely admit turning it back on for acceleration made it a lot more enjoyable to drive.

[Natalya]

Battery management... I'm still waiting for Linsight to come out hahahaha