2006 Honda Insight MT Build Thread

[mpg_numbers_guy]

That's true, but the position and size of the stock fan seem to allow for much better cooling. Even by feel the stock fan performs much better, even if the specs say differently. Really the only way to reduce sound is to reduce RPM, which reduces CFM unless the diameter is increased. A smaller and faster fan will blow less air but will blow faster; the meanwell is a closed unit so size of fan seems less important than how fast the air is moving through it. Actual cooling effect is also dependent on placement and airflow route, not just fan specs.

Going to continue running the stock fan as is for now; if it lacks in cooling I may add a beefier fan later. I don't particularly mind the excess noise, but it might be bothersome for a passenger. I wonder if there's a way to set up some sort of microcontroller to set different fan operation types, such as "comfort" where the fan only runs at lower speed up to a certain temperature before running full speed, "max cooling" for high speed all the time, and then "default" for default operation.

[mpg_numbers_guy]

Got a bit more done on the Insight today.

Meanwell and rectifier are now securely mounted to the aluminum bar I repurposed from the IMA compartment. Used thermal paste to ensure good heat transfer.









Installed a manual kill switch to disable the meanwell when parked/not in use to stop the 100 mA parasitic drain from the unit. It's just a basic marine battery kill switch that I hooked up to the ground connection.

With that all being done I built up the driver's side and got it ready for laying down board and carpet. Just have two more sections of foam board to install and then it'll be ready to lay down the plywood.

[mpg_numbers_guy]

Finished building up the floor with foam board and sound deadening. Next step is plywood, underlay, then carpet.

All the scraps of foam and whatnot will be removed once the build is done.

[NoD~]

Looks good so far! What did you build up with under the carpet padding? Such as where the kill switch is for your Meanwell setup. Things get a little quieter as you put more together I assume? With my bare trunk, the noise was INSANE! Putting as much absorptive materials around the wheel wells as possible makes all the difference, though!

[mpg_numbers_guy]

I used foam board to build it up and get a flat/level surface for the plywood. Used a knife to carve out the areas for the rises in the floor and electrical wiring. The underlay underneath the foam board prevents the foam board from squeaking in case it rubs against anything from vibrations on the road. The frame around the spare tire area is made of 2x4s cut in half to support the lid and prevent warping under use and weight.

It's definitely getting a bit quieter whenever I add stuff. I can't compare to stock since it's been a while since I've driven the Insight stock, but it's definitely quieter than when I had everything out.

[mpg_numbers_guy]

Took apart the rear drum brake assembly to figure out the parking brake issue I posted about earlier with this picture:



Turns out that the parking brake lever was missing--yes, missing--from the driver's side brake assembly. This is Honda part # 43371-SAA-004.

My theory then is that when the parking brake was engaged, the wire would be pulled forward without pulling the lever, and then since the lever was not there, the wire wouldn't retract, leaving the extra wire there and throwing off the 90 degree angle.

When I get the part installed, I'll need to readjust the parking brake, so I'll install my new S2000 e-brake handle at the same time.

Hoping that's all it is, getting the part ordered tonight.

Also, I'm getting Autostop with leanburnminactivationspeed set to 27 (22 mph). I didn't get it when set to 30 (25 mph), so I'll try setting it to 28 (23 mph) and see what happens.

[samwichse]

Somebody took that car to Midas for brakes.

No one screws up brakes like Midas.

[19bonestock88]

(In tune) Don’t let Midas touch!

Lol, can’t wait to see more, the build is looking great so far

[mpg_numbers_guy]

Yea, not sure what was going on there on the rear brakes. The brake worked okay - not perfect - when I bought the car, but has slowly gotten worse, probably as the wires have moved around from the driver's side not being connected.

No boards permanently installed yet on the rear rebuild; been working on fabricating them and getting a few frame pieces built. Got a squeak to locate tomorrow, probably the foam board rubbing against the kill switch that got moved a bit when test fitting plywood behind it. Waiting on the parking lever to arrive to fix the e-brake. Also had to order a part for the S2000 e-brake install - I'll update on that when it's installed. Both parts should get here Monday.

Passenger side test fit:



Driver's side test fit:



Hole cut for Meanwell area exhaust fan:



Nothing's attached yet, just building the pieces and test fitting. And waiting on stuff to arrive.

[Ecky]

Lookin' really good!