I'm pumped to report that the Insight 1G completed a transcontinental journey (approximately 3,000 miles) in the early morning (0130) on Friday 31JUL09 in Anacortes, Washington after leaving Dameron, Maryland on Sunday 26JUL09. The journey was completed without major mechanical difficulty. The most objectionable mechanical bug was a slight coolant leak which leant a faint maple syrup smell to the journey. Other than that it was: fuel, check oil, top off coolant, drive, pee, drive, eat, pee, drive sleep, drive, eat, fuel, etc.
It's a good thing the car has a relatively small 10 gallon tank. With a high of 92mpg (average speed approximately 57 mph with one person and 100 pounds of gear) on two legs totaling nearly 1,800 miles it was a physically trying experience watching the fuel gage eke towards empty. The other two legs completed rang in at 72mpg (average speed 55 mph with two people, 100 pounds of gear, and lots of time at idle trouble shooting before beginning the leg through the hill filled PA Turnpike) and 80mpg (average speed 60 mph with one person and 100 pounds of gear driving sub-optimally through mountain passes).
There's still some work left to be done on the car. Todd Humora has graciously offered additional electronics support even after a 3 AM thrash-fest to resolve some translator problems before the car left Maryland. The electric side isn't fully functional yet but that's been isolated to a wiring discontinuity which will be resolved soon. After the electric side is up and running Mike Dabrowski and Eric Smith have offered to help tweak it to better assist the VW engine. Additionally, the VW engine controller is throwing a few codes that may be related to our initial programming strategy and some wiring strategies on my part that aren't the best. And, there's still a bit more performance to be found by optimizing the VW engine controller tune for the Insight application (Mike Lane and Mark Malone are speaking beeps and squeaks in an effort to shine up the base program). Mark Phippen is going to take a crack at modding an oil pan for better ground clearance and I still have to scrounge up an emissions system that hits the Tier II Bin 5 mark.
At this point Bonneville is definitely in the cards. Dad and I cranked the car up to 75mph on the highway and it showed no signs of slowing down. By the way the car was pulling we think 100mph is on the low side of what's possible. Double nuts baby; 100mpg and 100mph. I can't say that I've seen another car on the public roads that can claim the same.
Despite the fact that we haven't broken 100mpg yet I think we're off to an astounding start. Using 15 year old technology we've created a vehicle that trounces any mass produced car in America in terms of fuel mileage. Based on the responses I've been getting we're beginning to raise some eyebrows:
http://forums.tdiclub.com/showthread.php?t=253045
http://www.insightcentral.net/forums/modifications-technical-issues/15151-1-2l-tdi-honda-insight-build-completed.html
http://www.99mpg.com/ProjectCars/redlightracingworl/
http://www.youtube.com/watch?v=XgELfyYsxyM .
Building cars to shame since 2007,
Jake
