The G1 Insight thread.

[Insight for life]

Originally Posted by cowmeat

took the throttle smoothing circuit off today, just waiting on your address to ship it out. I could not find the paperwork, but i'm sure the directions are on ic somewhere.

I also still have the old oem egr valve packaged up waiting on a taker. Qc, did you say you wanted it?

pm sent

[cowmeat]

Got the material for the full belly pan today.

I bought five sheets of 43" x 44" pallet liner for ten bucks. It's thin (like 3/16" deep at the most) heavy duty coroplast that they use to separate loads on pallets, so it's strong and light. Should work great, I'll install it in the morning after it warms up so I'll find out then.

[Ecky]

Where'd you get it, and how much did you pay?

A few days ago I went around town and picked up a bunch of random signs, and used them to construct my rear pan today. I cut up the sign holders to stick through the corrugation and give support, as well as hold the individual pieces together, since I'd be making it out of ~6 individual pieces.









I tucked it under the middle pieces, plus a few zip ties to support structures. I cut out around the exhaust and bent the coroplast up in that area to keep it from catching air. At some point I'd like to do a complete pan front-to-back using only a few pieces, replacing the stock panels, but this is an improvement as it covers some cavities.

[cowmeat]

Got them from a guy about fifteen minutes from my house who has a farm way out in the sticks. He has thousands of pallets, 55 gallon drums, and dogs and pigs running around.
I got all five sheets (I'll probably only need three of them but grabbed a couple extra) for 10 bucks. He sells them on Craigslist all the time, and apparently he actually gets shipments of them.

This guy has literally hundreds and hundreds of them in every imaginable color, and they're all two bucks each. If these work good on Turtle, and I fully expect them to, I can grab some for you if you want and throw them in my shed for next time you come through the area.

[Ecky]

Yeah, let me know how they work first but I'm interested.

[cowmeat]

Here's a pic with one laying right in front of the car so you get an idea of its size. I think three of them will cover the entire under surface.

[mikeyjd]

I'm jealous of all the fun you guys are having down there Nice deal on the coroplast!

[cowmeat]

Full belly pan is installed!

This one took a couple of hours and cost me thirty bucks (twenty bucks for the 3x3 aluminum), but in the long run it may pay for itself. Test run was great, no melting, overheating, no smoke, cabin heat, anything like that. The coroplast is rock solid, and I used aluminum over the cat and it's not discolored after half an hour on the road.

I mounted a steel bracket for the first sheet at the back (which I had laying around) and the second sheet mounted to a bracket behind the cat, and the sheet of aluminum over the cat screwed into the front bracket already in place for the front aero panel.
The entire car has a smooth underbody now, I'll see how it fares, and what kind of affect it has on mileage.

[Baltothewolf]

Hmm... You know if exhaust temps get over a certain degree, it can cause them to melt/cause engine problems (like melting the exhaust manifold). I would tread lightly covering the entire exhaust like that, it could cause serious long term side effects.

[cowmeat]

Yeah, I might drill holes through the cat area and exhaust area so the temps don't build up. I'll watch it this week and see if there are any funky signs, but so far so good