Stretch-Insight as Travel-Van Alternative

[cRiPpLe_rOoStEr]

Originally Posted by deejaaa

i've seen stretches on framed (how it's made) vehicles but never uni-body

I've already seen a handful of unibody vehicles stretched. Some had too much flex while others retained a good structural rigidity.

[Xist]

I can be pissier than you can!

Wait, no, too lazy...

[Xist]

Everybody knows that the cool kids stretch the body and then chop the roof!

[sheepdog 44]

It's possible in my opinion. There really is no structure in the rear besides the 4 mounting points for the rear suspension. The cabin is a good structural box with two rear aluminum curved bars coming out back for said mounts. The rest is not integral. You could cut all the sheet metal in the back out and it might drive fine. It's just for cosmetics and aerodynamics.

For space use the rear isn't flat on the bottom though. Only the spare wheel well cavity reaches the bottom. The rest is raised to where the ima box bolts on.

[basjoos]

Originally Posted by Xist

I am not sure that a stretched Insight would maintain its aerodynamics. Don't you have increased skin friction on flat surfaces?

What about an aerodynamic trailer?

A stretch could improve the aerodynamics by raising the fineness ratio from the 3 to 1 found in the stock Insight to a higher value, ideally around 5 to 1.

[Xist]

I always feel like Ecomodder.com is in grave peril when Xist jumps in to save the day with Windows Paint.



The original Insight is 3.945 meters (12 feet 11 5⁄16 inches)
Stretching the car from the apex back by one-third (oops) would make it 4.566 meters (14 feet 11 49⁄64 inches)
The proper 5:1 stretch would make it 5.187 meters (17 feet 7⁄32 inches)

[Ecky]

Just like to chime in with my experiences regarding the Insight and cargo capacity / aero trailers.

Although it's only rated from the factory for something like 450lbs of cargo + passengers (two large passengers can exceed that!), I've seriously exceeded that before, and had no issues with ground clearance, handling or power. Braking is another matter, but taking it slow really helps and hybrid braking makes a noticeable improvement.

I recently used my Insight to move from Florida to Vermont, and drove along the spine of the Appalachians with the following:

Myself, my wife, my border collie and my sheltie
~500lbs of stuff in the car
trailer loaded with 1000+ lbs
Total estimated in excess of 3500lbs, with the car coming in at ~1850lbs

We drove to the top of Clingman's Dome (6,650ft, 4,500ft relief), frequently WoT in 2nd gear @ 4000+ RPM, and had no problems with cooling even with an upper grille block. Going down the other side I experienced no brake fade, despite the grade being very steep at times. When on the open highway I was comfortable keeping up with traffic when necessary, and still averaged 57mpg with a target speed of 60mph over the 1,500 mile trip. Braking distances were a big long for comfort, so I kept my distance.

[sheepdog 44]

I've removed the IMA from Insight #2. There is enough space for a single rear facing seat in the spare wheel well, and i've removed enough weight to compensate for a 3rd person. The rear doesn't have a flat floor for a second rear seat. Many portions are maybe a foot higher than the floor. Would be easy enough to weld a flat floor in if you had the skills.

As far as camping in it, at 5'5 and 130lbs i've slept in the stock hatch and it was comfy. Slept great! Only you have to deal with warming the car with the engine off, and ventilation. You have to crack the windows and you quickly condense moisture on the glass.

[elhigh]

The teeny-tiny brakes in the Insight make me think adding some kind of trailer brakes - even el cheapo surge brakes - would be a good thing, if only for peace of mind.

Your towing setup looks the bomb. With a rig like that I could give up the truck, except I'm deeply in love with it.

[dremd]

I would try and find out what grade of aluminum the unibody is made out of, if it's 3000,5000 or 6000 I'd just weld it up. TIG would be best, but I pulse spray MIG 3003 .040 everyday.

I'm 100% sure it is possible to stretch an insight, but for 4 passengers you may consider going to a MKiV Jetta TDI wagon and aero modding that, yes much heavier, but not as drastic (or as cool) of mods required. That said, if you just need more cargo space, then I'd do a trailer behind insight.