Thought I'd share one of the most crucial updates since the Insight 1G project started nearly two years ago.
Tom Staub delivered on the adapter that we've been developing over the last few months. Because of the outlandish nature of what we're doing it's not like there's a crop of background material or experience to work from. It took a while to get all the dimensions and alignments correct for the CNC program that was used to cut our two piece adapter. The first piece in the set, which started life as a 27lb slab of aluminum, is used to mate the Honda electric motor casing to the VW diesel engine. The second piece, machined out of billet steel, mates the Honda electric motor rotor to the VW crankshaft. I'm happy to report that with some additional coaxing and modification via Mark Phippen and company the VW engine was fitted to the Honda electric motor in mid-May.
Getting the Honda and VW pieces to fit together was yet another crucial step in the build process. There have been many others along the way: 1. Vehicle acquisition (Lupo 3L specifically); 2. Data acquisition; 3. 1.2L Engine Control Unit development; 4. Translator box development.
One huge step that was recently tackled was fitting the VW/Honda power train combination in the Insight 1G. As our adapter ended up being approximately 1.4" thick and the power train is mounted longitudinally (East/West versus North/South) in the car we knew it was going to be a tight fit. If the combination fit at all. So, it was a happy moment when Mark Phippen and I slid the works into the car. There wasn't much room to spare but there was room. Another nail in the build coffin.
Yet another problem that kept us up late at night was fabricating a suitable engine mount. Again, we lost a lot of space with the thickness of our adapter. So, we had to get creative. Mark and I put our heads together to design and fab a minimum thickness engine mount using 4130 chromoly steel for the front of the engine. Our first effort and approach to the problem was a failure (not enough room). We nailed it on the second go. That's called learning from a mistake. There will be much more of that to follow.
The end result is that we now have a power train in the Insight 1G and are working at a steady clip on the details of the build. Primarily we're working on connections: 1. Exhaust; 2. Air intake; 3. Charge air cooler; 4. Coolant; 5. Fuel; 6. Wiring. While these are not mundane areas due to the custom nature of each the level of complexity of the build has dropped considerably. Although not a certainty, at this stage I think it safe to change Red Light Racing's vehicle status from possible to probable.
Keep an eye pealed for pictures to show family and friends. Again, the intent is to publish the details of the build in order for others to follow behind us and build their own hyper efficient diesel-electric hybrid to stomp the competition with.
Boat drinks,
Jake
