Honda Insight Tail Extension Project

[Joenavy85]

Just curious, what are the approximate dimensions of the flat on the end of the boattail(where the plate and taillights are mounted)?

[3-Wheeler]

Originally Posted by Joenavy85

Just curious, what are the approximate dimensions of the flat on the end of the boattail(where the plate and taillights are mounted)?

Maximum width is: 30.0 inches
Maximum height is: 9.5 inches.

Jim.

[3-Wheeler]

Well, I've been busy working on "mods" to the Insight for the last two months or so.

Several of the mods required taking the tail off the car about 5 weeks ago. After removing the tail and standing up on the large side of the tail, water was dripping out from inside the fiberglass! I could not believe it at first.

After further inspection, water from winter's snow and springs rains were making their way into the foam/fiberglass through water soaked passageways of Elmers Glue and soggy light-weight spackling.

The Elmers glue did not seem to be expanded but the spackling sure was, and puffed out the fiberglass in numerous places.

As this point it was a easy decision to remove the entire layer of glass on the underside of the tail. The attached photo shows what it looked like after removal.



You can see other pictures here...

https://picasaweb.google.com/threewh...04201986179906

Summary to this point:

Anyone contemplating making a foam/fiberglass composite structure should take the necessary steps to ensure that the entire structure is water tight.

Of course, my flimsy excuse is that I simply ran out of time when the weather last fall turned cold as it usually does this time of year.

Jim.

[aerohead]

I use the same excuse for myself.And I'd rather not admit to how many projects that have been reclaimed by the elements for the same reason.
I hope you can find it in your constitution to 'revisit' the project.
Just looking at your work makes me want to stay in the game 'till my days run out.And I think I speak for anyone who's seen it.

[Weather Spotter]

I left the bottom of my tail open a bit so that any water that gets into the tail can drain out.

[Cd]

I can't wait to see more images of the car with the tail. Especially from a distance showing the entire car. I have to say that your car looks almost natural with a full boattail.
Thanks for the detailed write up and images.

[Erc1727]

word!!! post 3 outta 10 so i can send a pm

[3-Wheeler]

Originally Posted by aerohead

....I hope you can find it in your constitution to 'revisit' the project....

Oh yes AeroHead, no problem there.

The car now feels incomplete without, and I can't help but think how many more MPG's I can get with it back on!

The motivation is high to continue until properly done. It may not be painted the color red this fall, but by golly it sure will be sealed up!

Jim.

[3-Wheeler]

Originally Posted by Weather Spotter

I left the bottom of my tail open a bit so that any water that gets into the tail can drain out.

Hi Weather,

I hear you on the comment about inside drainage to the outside world.

In my case however, the rain got into the fiberglass from the OUTSIDE.

There were several areas where the fiberglass on the bottom side ran all the way across, edge to edge, but not overlapping the existing glass running down from the sides.

End result was a "gap" that ran the length of both sides of the underside body work. And man did the water love that gap.

Once the water infiltrated the gap in glass, it found the Elmers Glue and decided to "soften it up a bit" and used that path as a way to travel wherever it wanted to.

Well travel it did, to every remote crock and cranny that it could find until the fiberglass said "uncle - enough".

Even the spackling got involved and softened right up under the pressure of the moist presence.

The motorcycle fairing that I made 15 years ago did not suffer the same abuse as it was constructed in the basement over the winter and when it emerged from the bowels of the basement, it was ready to rock and roll come rain or shower.

So now the objective is to get the "tail" ready for the same experience this fall.

Jim.

[MetroMPG]

Originally Posted by 3-Wheeler

Anyone contemplating making a foam/fiberglass composite structure should take the necessary steps to ensure that the entire structure is water tight.

I will echo this!

I had water wicking into my cardboard + fiberglass kammback (http://ecomodder.com/forum/showthrea...sion-3518.html ). I thought I had it well sealed, but nope.