So the next step in the build was the fuel system. The stock fuel pump in the Insight may well flow enough but I didn't want to keep a 250K mile fuel pump in the tank. I had an extra AEM 320L/hr pump available to me and decided just upgrade now incase forced induction falls from the sky.
I started by pulling the tank out of the car.
Then I pulled out the fuel pump assembly.
Next step was the measure the resistance of the fuel sender. I wanted to make sure I could match the correct highs and lows with S2000 cluster. This is pretty simple, just move the float to the top and measure the output at the pins, then the bottom and measure again.
Next I pulled the assembly apart to get to the fuel pump. Here is the old pump, next to the new pump.
Luckily the pump was easy to install. It fit in the stock cage and all of it just snapped back together.
For the fuel injectors I am using some Fuel Injector Clinic 525cc. All the injectors come with flow documentation to ensure they are within 1% of each other.
The last part of the fuel system is think Pro series fuel rail. I am running AN line and an Aeromotive regulator to finish it all out.
Now that the engine and the suspension are bolted in place, I could move forward with the brakes. I decided to go with EP3 Civic Si calipers and rotors. This is an easy bolt on upgrade and should help drag the ExSight down from high speeds during track days. I bought some new replacement calipers that were already paint red.
Then I got the most hilarous brake rotors from RockAuto. These are going to be replaced shortly, I promise. They are only temporary to make sure the setup works correctly. Best part is they were both $10 total. Haha
I wanted to use some stainless lines but the Insight has the mounting brackets permanently mounted to the lines. This meant I had to modify the brackets in order to use Civic Si brake lines.
Here is the bracket and the line to start.
Now we just cut the line off....
Weld it all back together...
BAM. All better.
Lets bolt them on the car.
Nice. They fit like stock.
Ok, now the rotors, calipers and Bosch pads can be bolted up.
Next I moved on to the sway bar. I used these nice collars from Fortune Auto as the old sway bar mounts were welded to the stock strut. They allowed me to bolt the stock sway bar back in place.
ev
And here is a final shot of the brakes, lines and sway bar. Everything is tied down and clear when the wheels are turned lock to lock.
Those rotors are ... distinctive. Any idea why they were dedigned that way?
DaewooOfDeath wrote:
Those rotors are ... distinctive. Any idea why they were dedigned that way?
No idea who thought that was a good idea. I will say again, $10 total. DBA rotors will be here soon. haha
The finished product here is going to be a very impressive car.
Nitroracer wrote:
The finished product here is going to be a very impressive car.
I am working hard to make this car nice. Once I am done I don't want to have to work on it all the time. I want to be able to enjoy it.
I approve of your entire philosophy with this build. Carry on!
I know I have been lacking updates and I am sorry about that. The ExSight is now running and I took it to an autox last weekend. It was the first time its been run in anger since its been on the road. It did really well, one of the fastest car of the day not on slicks. Not bad considering I got 49 mpg on the way there and back.
Heres a link to the video.
ExSight Autox
tuna55 wrote:
WOW!
Wow is a good thing right? Haha
tuna55
MegaDork
4/11/16 1:59 p.m.
ProAweMike wrote:
tuna55 wrote:
WOW!
Wow is a good thing right? Haha
The power/fun/efficiency combo is pretty much unbeatable. That kind of wow. You made one of the best street cars ever.
This will surprise people.
tuna55 wrote:
ProAweMike wrote:
tuna55 wrote:
WOW!
Wow is a good thing right? Haha
The power/fun/efficiency combo is pretty much unbeatable. That kind of wow. You made one of the best street cars ever.
I think its pretty cool as well.
More work to do, always improving but its a pretty great little car.
tuna55
MegaDork
4/11/16 2:42 p.m.
ProAweMike wrote:
tuna55 wrote:
ProAweMike wrote:
tuna55 wrote:
WOW!
Wow is a good thing right? Haha
The power/fun/efficiency combo is pretty much unbeatable. That kind of wow. You made one of the best street cars ever.
I think its pretty cool as well.
More work to do, always improving but its a pretty great little car.
How much would it cost to replicate this, roughly?
I went way overboard with a bunch of stuff. If you wanted to keep it cheaper but still nice it would be about 4k plus the car. I am really happy with the comfort and the capabilities of the car. Its a great all around performer.
tuna55
MegaDork
4/11/16 3:19 p.m.
ProAweMike wrote:
I went way overboard with a bunch of stuff. If you wanted to keep it cheaper but still nice it would be about 4k plus the car. I am really happy with the comfort and the capabilities of the car. Its a great all around performer.
That's really quite impressive. Nicely done.
Build me one? Turn key? $10 grand ok?
ProAweMike wrote:
I know I have been lacking updates and I am sorry about that. The ExSight is now running and I took it to an autox last weekend. It was the first time its been run in anger since its been on the road. It did really well, one of the fastest car of the day not on slicks. Not bad considering I got 49 mpg on the way there and back.
Heres a link to the video.
ExSight Autox
It moves! With traction, I'd be curious what this thing does down a drag strip. I knew several EG's with similar power numbers from K swaps running high 12's NA with slicks. I reckon this weighs a little less than that so 13s on street tires should be no problem.
Petrolburner wrote:
Build me one? Turn key? $10 grand ok?
Haha. I'll let you know if I start building them for people. I plan on selling parts for these cars as there is a small following.
crankwalk wrote:
ProAweMike wrote:
I know I have been lacking updates and I am sorry about that. The ExSight is now running and I took it to an autox last weekend. It was the first time its been run in anger since its been on the road. It did really well, one of the fastest car of the day not on slicks. Not bad considering I got 49 mpg on the way there and back.
Heres a link to the video.
ExSight Autox
It moves! With traction, I'd be curious what this thing does down a drag strip. I knew several EG's with similar power numbers from K swaps running high 12's NA with slicks. I reckon this weighs a little less than that so 13s on street tires should be no problem.
Ohhhhh there was noooooo traction. That is GPS speed, wheel speed looks much different. haha. I am shooting for 12.50s. its 1880lbs wet so I hope I can pull that off. That is one of the goals of the project.
ProAweMike wrote:
crankwalk wrote:
ProAweMike wrote:
I know I have been lacking updates and I am sorry about that. The ExSight is now running and I took it to an autox last weekend. It was the first time its been run in anger since its been on the road. It did really well, one of the fastest car of the day not on slicks. Not bad considering I got 49 mpg on the way there and back.
Heres a link to the video.
ExSight Autox
It moves! With traction, I'd be curious what this thing does down a drag strip. I knew several EG's with similar power numbers from K swaps running high 12's NA with slicks. I reckon this weighs a little less than that so 13s on street tires should be no problem.
Ohhhhh there was noooooo traction. That is GPS speed, wheel speed looks much different. haha. I am shooting for 12.50s. its 1880lbs wet so I hope I can pull that off. That is one of the goals of the project.
Oh no I was saying WITH traction I wonder what it would run. I could tell you didn't have any there. You need some proper slicks for that thing at a drag strip. God, an Insight running 12.50s all motor is like stock C5 Z06 all motor numbers.
Haha. I see what you meant now. That's exactly what I was shooting for, C5 Z06 performance numbers with double the fuel economy.
I would be very interested in a ProAweMike K-Sight fabrication patch batch (improved mounts, necessary modified brackets, 3D parts, etc) necessary to make this swap a reality for those with limited fab resources and/or skills. There's an enticing Insight near me that is limping it's CVT and the IMA is long dead. My aspirations are much lower, a K24 out of an Accord or CRV, complete DD build that has no intentions of serious track time. Still plenty of scoot at 45+ mpg.
Makitadiesel wrote:
I would be very interested in a ProAweMike K-Sight fabrication patch batch (improved mounts, necessary modified brackets, 3D parts, etc) necessary to make this swap a reality for those with limited fab resources and/or skills. There's an enticing Insight near me that is limping it's CVT and the IMA is long dead. My aspirations are much lower, a K24 out of an Accord or CRV, complete DD build that has no intentions of serious track time. Still plenty of scoot at 45+ mpg.
I have now started producing some of these components so people can build their own ExSight. I will soon have them up on www.ProfessionalAwesome.com for sale. Check it out if you are interested.
I am extremely interested. I even test drove a 1g insight a little bit ago.
