2006 Honda Insight MT Build Thread

[mpg_numbers_guy]

Thanks! Both the armrest and headlights have done well for the 10 miles I've driven since installing them. Now for those 700 miles back to college this weekend.

[mpg_numbers_guy]

Tried 80 PSI in my tires for the trip down to college post-spring break instead of my normal 60 PSI. Insight performed amazing - 85.3 MPG over 705.2 miles. 88.3 MPG for the first leg, and 82.1 MPG over the last leg that's mostly mountains. Was averaging ~10 MPG better going up the mountains, ~15 MPG better at speeds <50 MPH, and ~5 MPG better at speeds >50 MPH. Of course the IMA is still disabled for better highway fuel economy.

For comparison:
First trip to college with the car: 78.2 MPG
Spring break trip home: 78.4 MPG

Only fuel economy modifications since last trip were a 3' x 3' underbody panel, 80 PSI in the tires, and a warm air intake that actually works now.

Temp varied between 31 and 49 degrees F. Cruising speed varied between 40 MPH (up the steepest mountains) and [insert incriminating speed] MPH on the downhills. Trip time was the same as the other trips.

[mpg_numbers_guy]

I love summer weather! Okay, well not summer weather yet up north, but definitely warm enough to get good mpgs.

Return trip from college, new tank record 85.7 MPG over 705.0 miles:
- Day 1: 80.8 MPG through the mountains and hills in the Virginias and southern Ohio
- Day 2: 92.5 MPG on mostly flat highway through Ohio, Indiana, and Michigan (trip record!!)

I hadn't driven the Insight since taking it back down to college after spring break, so this warm weather was a plus.

Mom followed in the Prius and got 57.8 MPG the first day and 62.5 MPG the second day. She's officially better than me at hypermiling the Prius. This busts my theory that my Civic with ecomods was more fuel efficient than a Prius. With ecomods and hypermiling I could get in the 50s on the highway, and did reach 60 MPG once with a tailwind, but the Prius completely smoked that today by a good 5%, at least.

Had problems with my 12V battery staying charged after disabling the IMA, so I followed the advice of a few Insight Central experts and cut the WHITE/GREEN wire on the DC-DC connector to prevent it from going into low power mode and only charging the 12V to 12.5-12.9V. Now the 12V stays happily charged from 13.9-14.3 volts.

Now that I'm back home, summer plans! Have a decently sized list of mods I'm hoping to get done this summer, including completely removing the IMA, upgrading speakers, and recarpeting the floor post-IMA delete. We will see how much I get done!

[mpg_numbers_guy]

Gutted the rear of the Insight in preparation for complete IMA removal. Left the IMA battery installed (but disabled) until I can get the bypass installed (waiting on Ecky's awesome k-swap).

It's crazy how much storage space is wasted for battery cooling.





Here it is done where I stopped for the day:





Also removed the door speakers for replacement. Pretty sure the passenger one was shot.

[samwichse]

If I were you, I'd probably leave the Tom Mix and attached aluminum plate in. They don't really cost you any space, and they tie the sides of the car together. And help protect you from what's in the back in the event of a collision. Plus you can put speakers in there and keep the factory carpet in that location.

[Vman455]

I was just thinking, it's too bad that aluminum bulkhead looks like it serves a structural purpose. If you could leave it out and build a flat load floor, you could have a ton of space inside of a tiny car!

[mpg_numbers_guy]

The gas tank behind the seat prevents an ultra low floor, unfortunately, but there is still a decent amount of storage space to be gained.

Regarding the aluminium bar, I will probably put it back in the car, but taking it out for now makes it easier to get the battery out and new floor laid.

Does the bar really help structural integrity? Thought it was more to help keep the IMA in place. Ecky removed his when he deleted the IMA and rebuilt the rear.

Not sure if I'll reuse the aluminum back plate, or make a new one. There's a bit of storage on the sides behind the seats I could use for my tools instead of having them in the back that woukd be lost if i covered it up with that plate.

Still working on the layout of how I want to rebuild it. I'll have a better idea of how I can work with it once I have a permanent bypass installed and the IMA battery out.

Eyeing some Polk speakers on sale to replace the crappy OEM ones too.

[fusion210]

I was under the impression that these bars were for side impacts.

I had a 1998 neon coupe and it had one directly in front of the rear seat's bottom cushion. It was attached to the pan where the bottom seat snaps in, but extended through the body out to the sides of the car behind the doors.

[Ecky]

Originally Posted by fusion210

I was under the impression that these bars were for side impacts.

I had a 1998 neon coupe and it had one directly in front of the rear seat's bottom cushion. It was attached to the pan where the bottom seat snaps in, but extended through the body out to the sides of the car behind the doors.

That's my understanding - it helps to prevent the side of the car fromo collapsing.

Mine is gone, and I'm not concerned. Statistically lots of people die from side impacts, but also my chances of getting a side impact are incredibly small.

[mpg_numbers_guy]

I was messing around back there yesterday and I think I cam leave that bar in place without really losing any storage space, and it'll make fabrication there a bit easier.

I'm wanting to relocate the back speakers though, since the stock position just has them cramped behind the seats.

If you remove the sound deadening, there's room for the spare tire between the DC-DC and the side of the car, which would open up that spare tire area for storage, but the spare tire is supposed to be part of crash protection, so plan is just to leave it there.