Insight modding

[Sigma Projects]

Well, I can't just leave anything alone. So first part on modding is the suspension on the Insight. Since so few have been made there is really no aftermarket support, I mean none, you have to go to the dealer to get parts. Hmm no aftermarket support, part swap and custom modding, sounds familiar!

So, I decided to mod some Civic Si/RSX coilovers. The bolt spacing for where the struts mount to the hubs was very close, steering arm position is pretty close also although the steering arm is shorter on the RSX coilovers, hoping for a bit quicker steering and the steering feel is pretty decent already. Also I have to get coilovers because the stock struts have very small springs and normal size springs won't fit in its place. And a set of Godspeed Mono RS coilovers is about the same price for two Honda struts... yea they're like $300/ea

So first part on my list is widening the strut mount at the bottom.

I should have it welded up tomorrow

next is the new guides for drilling new spots in the top hat for the camber plate so it will mount up in the factory location. I want to avoid cutting into the chassis or modifying any of the Insight's parts since they aren't super common.

Also the template will provide as a test fit for making the new bracket for the engine torque mount since they never came with one and the factory engine mounts are extremely soft.

If all goes well then I can mount the new front coilovers next week. The rear is going to be a challenge and still trying to figure how i can use these RSX rear coilovers for it. Also planning on stiffening the rear torsion axle since others have had great success in helping with the balance of the car.

I got the biggest dunlops direzzas I could fit on the stock wheels (super light). Funny thing is 185/60R14 is the smallest sport tire I could find that was easily accessible, original tire size was 165/70R14.

[Sigma Projects]

Here's the simple prototype for the bolt spacing.

[Sigma Projects]

Yes ugly welds, but they're strong, the brackets moved slightly and needed to open it up another millimeter and was extremely difficult with a pry bar. So I'm not worried about the welds. Besides, this is for the honda, not the Celica, so it doesn't have to be perfect



now gotta modify the camber plates, going to be fauncy.

[Teranfirbt]

That done with a wire feed? Not gonna lie, I wouldn't trust those welds for any kind of driving.... Don't forget, you're trusting your life there.

[Sigma Projects]

I know it should be tig welded. The other side is tig welded and the brackets are originally for a car that weighs 50% more. They are for sure way stronger than the brackets that were original to the car.

[Teranfirbt]

Don't really have to be TIG welded, just need to be welded well. The main issue I see with those is that there's a ton of weld piled up between the plates and the tubes, but not much bite into either. Each of those little crevices is a potential spot for a crack to form and propagate, which will lead to eventual failure.
It doesn't matter how strong the parts are, the welds are generally your failure point on assemblies like this.
I seriously wouldn't drive on those until all of that weld was ground out and done properly. If you need some instruction, look up welding tips and tricks on YouTube, dude does some awesome videos. Hell, I'll weld them out correctly for cost of return shipping if you want

[ozzie]

Even an arc welder could give a good weld, I wouldn't trust those either.

[Sigma Projects]

I guess it's just not apparent in the picture, but the metal was chamfered and it's been passed over 3 times (partly why it looks ugly) as well on the inside, the bracket isn't going anywhere and I doubt it will crack.

[Toy Snake]

AJ, don't pay any attention to the comments.  All you need to do is grind the weld down a little and throw the whole thing in the trash!  That is really bad even if it is going on a Honda.....  .

[Sigma Projects]

I didn't expect this many people to be that scared.

[Teranfirbt]

This is a case where succumbing to peer pressure will be a good thing
Offer is still on the table, I'll weld em up right for whatever it costs to ship them back to you.

[Sigma Projects]

Still alive No problems so far and have beaten on it pretty good, if it's gonna break it'll probably break after I'm dead.

I'm planning on doing something in the back that doesn't seem as easy and looking for some premade brackets. I remember someone showing an online vendor that wasn't summit racing, anyone have suggestions outside of summit racing?

[Sigma Projects]

It's been a long time. I've been distracted by this dang aluminum can on wheels But it's quite fun to mod this little guy. Still learning new stuff so I can properly apply what I learn on the Celica.

I've since put in new shocks, springs all around and widened the rear track to be closer to the front track width.  Also shimmed the rear wheels to reduce some of the toe in.



Replaced my worn out control arms with new ones, but took out the fat soft rubber on the trailing portion and stuck in a poly bushing.


Built a new transmission utilizing the first gen Civic Hybrid case and Honda Fit gearing to get rid of the horrendously tall gearing in the car.




I had to make my owner puller tool to check thrust clearance on the main shaft. Damn you honda.


I was missing some of the front underbody aero bits so I picked up one of these one pieces that another Insight owner makes.


My stock wheels were looking pretty haggard to me and when I saw a deal for some 14" Volk CE28s (6.5lbs!) I had to snag them up.


I deleted the rear wiper since it always felt pretty useless whenever I would use it.


The headliner started to come down so I put on something a bit more fun This is my first time doing a head liner and I have to redo it, but still fun.



I still have a laundry list of things I got for it, but it's all fun. And yes, those ugly welds are still holding just fine after all these years and I've hit some pretty hard bumps too, one time I hit a pot hole that shook the car so violently that my can of fix-a-flat went off in the trunk.

[twotone_ra64]

Looking great dude! I still love the Persian inspired headliner. 

[Sigma Projects]

Looking great dude! I still love the Persian inspired headliner. 

I just couldn't help it when I saw the fabric