User:Rjf/Willies Red Rocket - Revision history

Rjf: EAA-PHEV:Insight PHEV

2008-09-27T23:03:06Z

EAA-PHEV:Insight PHEV

65.175.253.116 at 21:01, 7 July 2008

2008-07-07T21:01:36Z

67.174.90.234: /* PostTurbo */

2007-12-09T16:35:09Z

PostTurbo

Rjf: /* Photos */

2007-02-27T05:38:20Z

Photos

Rjf at 05:14, 27 February 2007

2007-02-27T05:14:58Z

Rjf: Initial Page.

2007-02-27T05:13:26Z

Initial Page.

Show changes

@@ Line 4: / Line 4: @@
 == Discussion ==
 * [http://www.insightcentral.net/forum/viewtopic.php?t=253 InsightCentral.net] Discussion
 * [http://autos.groups.yahoo.com/group/honda-hybrid/message/11458 Turbocharged Insight], Larry "WILLIE"

@@ Line 51: / Line 51: @@
 <B><I><U><P>OBJECTIVE</B></I></U>:</P>
-<P>1) In doing the modifications, to allow the return to a stock engine status with a minimum of work. <B>(In case the goal is unobtainable.)  </P>
+<P>1) In doing the modifications, to allow the return to a stock engine status with a minimum of work. <B>(In case the goal is unattainable.)  </P>
 </B><P>2) To keep the cost of the modifications as low as possible. <B>(A budget of $1,000.00)</P>
 </B><P>3) To complete the modification with a minimum of outside assistance. <B>(No one else to</P>
@@ Line 58: / Line 58: @@
 <P>     &quot;sleeper&quot;.)</P>
-</B><P>5) Install the modifications so that if future work is done, access would be non restrictive. </P>
+</B><P>5) Install the modifications so that if future work is done, access would be non-restrictive. </P>
 <P>6) Complete the modifications in a reasonable amount of time. <B>(90 days include testing.) </P>
 </B>
@@ Line 90: / Line 90: @@
 </B>
 <B><I><U><P>PRIOR MODIFICATIONS:</P>
-</B></I></U><P>Modification of the vehicle include speed stripes (white), the upper 6 in of the windshield tinted, a self constructed aluminum  foot rest in the drivers compartment, a &quot;T&quot; handled aluminum Hurst shifter, a longer rear window wiper blade, Visor Vents, and wider Goodyear rear tires while keeping the standard Bridgestone tires on the front. Additional Instrumentation added includes  2 red LED gauges to monitor the voltage in the 12V and 144V battery, a vacuum/boost gauge, and an air conditioner compressor &quot;on&quot; indicator light. All of the routine maintenance and service tasks have been performed by a dealer or me the at the required mileage.  </P>
+</B></I></U><P>Modifications of the vehicle include speed stripes (white), the upper 6 in of the windshield tinted, a self constructed aluminum foot rest in the driver's compartment, a &quot;T&quot; handled aluminum Hurst shifter, a longer rear window wiper blade, Visor Vents, and wider Goodyear rear tires while keeping the standard Bridgestone tires on the front. Additional instrumentation added includes  2 red LED gauges to monitor the voltage in the 12V and 144V battery, a vacuum/boost gauge, and an air conditioner compressor &quot;on&quot; indicator light. All of the routine maintenance and service tasks have been performed by a dealer or me the at the required mileage.  </P>
 <P>        </P>
 <B><I><U><P>OWNER &amp; BUILDER BACKGROUND:</P>
-</B></I></U><P>I am 62years old, divorced, and retired after 22 years in Law Enforcement. I had 18 years experience as a motorcycle mechanic, prior to changing careers and entering that profession. During the years as a mechanic, I raced both <B>AMA, FIM</B>. and <B>ACA</B> as a &quot;privateer&quot;. I also participated in the Bonneville Speed Trials and still hold a record there in the  A-C-200 class for motorcycles. <B>(1970). </B>I own a <B>1998 NASCAR SPECIAL EDITION</B> Ford F-150 pickup and a <B>Turbocharged 2300cc </B>(Ford Powered) dune buggy which I usually drive in the Dunes at Glamis, Calif. I do the modifications, and maintenance on all of my vehicles. I bought the <B>INSIGHT</B> for it’s looks and technical innovations.  </P>
+</B></I></U><P>I am 62years old, divorced, and retired after 22 years in Law Enforcement. I had 18 years experience as a motorcycle mechanic, prior to changing careers and entering that profession. During the years as a mechanic, I raced both <B>AMA, FIM</B>. and <B>ACA</B> as a &quot;privateer&quot;. I also participated in the Bonneville Speed Trials and still hold a record there in the  A-C-200 class for motorcycles. <B>(1970). </B>I own a <B>1998 NASCAR SPECIAL EDITION</B> Ford F-150 pickup and a <B>Turbocharged 2300cc </B>(Ford Powered) dune buggy which I usually drive in the Dunes at Glamis, Calif. I do the modifications and maintenance on all of my vehicles. I bought the <B>INSIGHT</B> for its looks and technical innovations.  </P>
 </FONT><B><U><FONT FACE="Times New Roman" SIZE=5><P>ON TO THE CHALLENGE-----------------------------------</P>
@@ Line 100: / Line 100: @@
 <P>                   </P>
 <B><I><U><P>THE TASK:</P>
-</B></I></U><P>Numerous hours of research, talking to individuals who are knowledgeable in building engines for performance, from my personal experience, and the goal and objectivity of the task at hand, I decided that the only modification needed was the addition of a <B>TURBOCHARGER</B>. The design of the engine; being a &quot;low friction&quot; type, overhead camshaft, having four valves per cylinder, needle rocker shaft bearings, aluminum rocker arms, a long stroke, compression ratio of 10.8-1,  and especially the <B><U>&quot;off set cylinder line&quot;  </B></U>were the key factors in my decision. Having installed a turbocharger before on my dune buggy, I knew of the concept and had a working knowledge of the system. After doing extensive research for aftermarket speed parts for the Insight,  I found that there was nothing available.    </P>
+</B></I></U><P>Numerous hours of research, talking to individuals who are knowledgeable in building engines for performance, from my personal experience, and the goal and objectivity of the task at hand, I decided that the only modification needed was the addition of a <B>TURBOCHARGER</B>. The design of the engine; being a &quot;low friction&quot; type, overhead camshaft, having four valves per cylinder, needle rocker shaft bearings, aluminum rocker arms, a long stroke, compression ratio of 10.8-1,  and especially the <B><U>&quot;off set cylinder line&quot;  </B></U>were the key factors in my decision. Having installed a turbocharger before on my dune buggy, I knew of the concept and had a working knowledge of the system. After doing extensive research for aftermarket speed parts for the Insight,I found that there was nothing available.    </P>
 <P>                                                     <B><U>PARTS NEEDED</P>
@@ Line 124: / Line 124: @@
 <B><I><U><P>7)IGNITION:</P>
-</B></I></U><P>No changes would be attempted in the ignition system. Timing is set at 12 degrees btdc and would be more than adequate for my needs. I was unable to find any specifications or perimeters for the &quot;knock sensor&quot; and hoped it will do it’s task when dealing with the high compression (15.1+-1) while under boost.  </P>
+</B></I></U><P>No changes would be attempted in the ignition system. Timing is set at 12 degrees BTDC and would be more than adequate for my needs. I was unable to find any specifications or perimeters for the &quot;knock sensor&quot; and hoped it will do it’s task when dealing with the high compression (15.1+-1) while under boost.  </P>
 <B><I><U><P>8)INJECTORS:</P>

@@ Line 385: / Line 385: @@
 <P><B>OWNER & BUILDER BACKGROUND:</B>
-<BR>I am 62 years old, divorced, and retired after 22 years in Law Enforcement. I had 18 years experience as a motorcycle mechanic, prior to changing careers and entering that profession. During the years as a mechanic, I raced both AMA, FIM. and ACA as a \privateer/. I also participated in the Bonneville Speed Trials and still hold a record there in the  A-C-200 class for motorcycles. (1970). I own a 1998 NASCAR SPECIAL EDITION Ford F-150 pickup and a Turbocharged 2300cc (Ford Powered) dune buggy which I usually drive in the Dunes at Glamis, Calif. I do the modifications, and maintenance on all of my vehicles. I bought the INSIGHT for it's looks and technical innovations.
+<BR>I am 62 years old, divorced, and retired after 22 years in Law Enforcement. I had 18 years experience as a motorcycle mechanic, prior to changing careers and entering that profession. During the years as a mechanic, I raced both AMA, FIM. and ACA as a \privateer/. I also participated in the Bonneville Speed Trials and still hold a record there in the  A-C-200 class for motorcycles. (1970). I own a 1998 NASCAR SPECIAL EDITION Ford F-150 pickup and a Turbocharged 2300cc (Ford Powered) dune buggy which I usually drive in the Dunes at Glamis, Calif. I do the modifications, and maintenance on all of my vehicles. I bought the INSIGHT for its looks and technical innovations.
 <P><B>ON TO THE CHALLENGE</B>
@@ Line 416: / Line 416: @@
 <LI><B>IGNITION:</B>
-	No changes would be attempted in the ignition system. Timing is set at 12 degrees btdc and would be more than adequate for my needs. I was unable to find any specifications or perimeters for the \knock sensor/ and hoped it will do it's task when dealing with the high compression (15.1+-1) while under boost.
+	No changes would be attempted in the ignition system. Timing is set at 12 degrees btdc and would be more than adequate for my needs. I was unable to find any specifications or perimeters for the \knock sensor/ and hoped it will do its task when dealing with the high compression (15.1+-1) while under boost.
 <LI><B>INJECTORS:</B>
@@ Line 544: / Line 544: @@
 <P><B>STOCK INSIGHT</B>
-<BR>The standard Insight has always been a fun car to drive. You can get excellent gas mileage and still have adequate performance to keep up with traffic.  I've always driven the Insight as a sports car, and let the mileage take care of itself. The engine appears to be real comfortable around 3000 rpm. Gas mileage is still adequate and the engine is  starting to pull good. Once you reach 4200 rpm the car accelerates at a brisk rate all the way to redline rpm which is 6000. Maximum torque is reached at 4800 rpm and maximum horsepower is achieved at 5700 rpm. I have experimented with the mileage and my high mileage is 96.4 miles per gallon for 114 miles. I don't average less than 100 miles for an average \miles per gallon./ If the vehicle is driven as a regular car, mileage of 60+ is possible. Insights driven in flat terrain, low elevation, and below average speeds will get much better. I find that most people rely too much on the IMA assist and then complain because the IMA battery won't stay up to it's capacity. If the battery level gets depleted to where there is no assist, a downshift is required to a lower gear and the engine run above 3000 rpm to charge up the IMA battery. Some people shift at a very low rpm to get full use of the IMA and to me that is causing an excessive load on the engine and components. The engine was designed as a low friction type and rpm wear is greatly lessened over a conventional engine. My procedure is to accelerate briskly, shift around 4000-5000 rpm and then throttle back for cruising for freeway or highway road speeds. I do not constantly short shift, as recommended by some Insight drivers.  By using all the gears most of the time, the engine is never under a severe load. Using this type of driving, my lifetime average miles per gallon is 59.6. I keep my tires inflated to 48-50 psi and have not had any ill effects from those tire pressures.
+<BR>The standard Insight has always been a fun car to drive. You can get excellent gas mileage and still have adequate performance to keep up with traffic.  I've always driven the Insight as a sports car, and let the mileage take care of itself. The engine appears to be real comfortable around 3000 rpm. Gas mileage is still adequate and the engine is  starting to pull good. Once you reach 4200 rpm the car accelerates at a brisk rate all the way to redline rpm which is 6000. Maximum torque is reached at 4800 rpm and maximum horsepower is achieved at 5700 rpm. I have experimented with the mileage and my high mileage is 96.4 miles per gallon for 114 miles. I don't average less than 100 miles for an average \miles per gallon./ If the vehicle is driven as a regular car, mileage of 60+ is possible. Insights driven in flat terrain, low elevation, and below average speeds will get much better. I find that most people rely too much on the IMA assist and then complain because the IMA battery won't stay up to its capacity. If the battery level gets depleted to where there is no assist, a downshift is required to a lower gear and the engine run above 3000 rpm to charge up the IMA battery. Some people shift at a very low rpm to get full use of the IMA and to me that is causing an excessive load on the engine and components. The engine was designed as a low friction type and rpm wear is greatly lessened over a conventional engine. My procedure is to accelerate briskly, shift around 4000-5000 rpm and then throttle back for cruising for freeway or highway road speeds. I do not constantly short shift, as recommended by some Insight drivers.  By using all the gears most of the time, the engine is never under a severe load. Using this type of driving, my lifetime average miles per gallon is 59.6. I keep my tires inflated to 48-50 psi and have not had any ill effects from those tire pressures.
 <P><B>WITH TURBO minus the EXTRA INJECTOR</B>
@@ Line 550: / Line 550: @@
 <P><B>WITH TURBO AND EXTRA INJECTOR</B>
-<BR>By using the maximum boost, without actuating full throttle the \G force/ was definitely felt. The turbocharger started to assist the engine at app. 3,000 rpm and really started to accelerate the vehicle at app. 4,000 rpm. even before the engine reached it's maximum torque at 4,800 rpm. The IMA was still being shown fully activated at 5,800 rpm. The BOV functioned as required at that shift point emitting a \sneeze/. No excessive under hood temperatures were encountered during the final testing with the 4th Injector functioning. The \boost light/ came on at one pound of boost and stayed on till boost was deactivated by closing the throttle. The LIGHT and monitoring of the BOOST GAUGE will allow the exceptional high mileage of the Insight to be maintained. It also seems that to maintain a specific mph, it takes less throttle than before, especially above 70 mph. It also appears that the IMA assist doesn't have to work as hard at the times it is used. When the IMA battery is depleted, (no more assist) activate the boost a little, acceleration begins and the battery starts to \regen/ even while accelerating up hill.  Acceleration up a slight grade in 5th gear above 80 mph can be done at will. A problem developed where as at sea level, actually \0/ ft. in altitude, the \boost/ light would come on when in idle stop. On further testing and evaluation, it was learned that the 4th injector was being activated at 2 in. of vacuum instead of .5 pounds of \boost\. This was apparently because all the setting were made at an altitude of  app. 2,500 ft. Further adjustments to the additional efi controller will be done so the 4th injector is activated at 2 pounds of boost at 2,500 ft. elevation. It will still have the maximum injector width at 6,000 rpm. This will cure the problem of the injector being activated while driving at sea level altitude and at 2 inches of vacuum. After the adjustment, the injector will come on at .5 pounds of \boost/ at sea level, right after the IMA activates.
+<BR>By using the maximum boost, without actuating full throttle the \G force/ was definitely felt. The turbocharger started to assist the engine at app. 3,000 rpm and really started to accelerate the vehicle at app. 4,000 rpm. even before the engine reached its maximum torque at 4,800 rpm. The IMA was still being shown fully activated at 5,800 rpm. The BOV functioned as required at that shift point emitting a \sneeze/. No excessive under hood temperatures were encountered during the final testing with the 4th Injector functioning. The \boost light/ came on at one pound of boost and stayed on till boost was deactivated by closing the throttle. The LIGHT and monitoring of the BOOST GAUGE will allow the exceptional high mileage of the Insight to be maintained. It also seems that to maintain a specific mph, it takes less throttle than before, especially above 70 mph. It also appears that the IMA assist doesn't have to work as hard at the times it is used. When the IMA battery is depleted, (no more assist) activate the boost a little, acceleration begins and the battery starts to \regen/ even while accelerating up hill.  Acceleration up a slight grade in 5th gear above 80 mph can be done at will. A problem developed where as at sea level, actually \0/ ft. in altitude, the \boost/ light would come on when in idle stop. On further testing and evaluation, it was learned that the 4th injector was being activated at 2 in. of vacuum instead of .5 pounds of \boost\. This was apparently because all the setting were made at an altitude of  app. 2,500 ft. Further adjustments to the additional efi controller will be done so the 4th injector is activated at 2 pounds of boost at 2,500 ft. elevation. It will still have the maximum injector width at 6,000 rpm. This will cure the problem of the injector being activated while driving at sea level altitude and at 2 inches of vacuum. After the adjustment, the injector will come on at .5 pounds of \boost/ at sea level, right after the IMA activates.
 <BR>After app. 3,260 miles of testing, the task is done and the project is considered complete. The MPG average over 3260 miles of testing, mostly at an altitude of 2,500 ft. is indicated at 55.6 per the FCD gauge. My lifetime miles per gallon is still at 59.6.
 <BR>By concentrating on boost control over  large throttle opening, acceleration is smooth and mileage doesn't appear to suffer. Only extensive testing under a controlled scenario would show a valid comparison.

@@ Line 13: / Line 13: @@
 == Photos ==
+<gallery>
+Image:Fe05-006.jpg|Here is the start of the project.
 ==ShowTurbo==

@@ Line 1: / Line 1: @@
 '''Welcome, This page is all about Willies' Red Rocket !!'''
-Discussion:
+== Discussion ==
-* [http://www.insightcentral.net/forum/viewtopic.php?t=253">InsightCentral.net] Discussion
+* [http://www.insightcentral.net/forum/viewtopic.php?t=253 InsightCentral.net] Discussion
 * [http://autos.groups.yahoo.com/group/honda-hybrid/message/11458 Turbocharged Insight], Larry "WILLIE"
 * [http://autos.groups.yahoo.com/group/honda-hybrid/message/11445 e-ram (thread)], Marc Webb.