BlueBird1

Jaybird trucking does another great transport.

Blue Birds story starts here, and continues at the bottom of the page.
I put up this blog for all the other Insight fans that are interested in what is under the covers of their baby.

As I tear it down and put the components on a test stand for a unique training tool, I will explore some of the seldom seen or understood aspects of this first of all Hybrid automobiles.

BlueBird1
Blue Insight arrives "Blue Bird"

Almost stripped

Almost stripped
Nearly Stripped
Ian and I removed the front end struts and wheels, the brake assembly. I removed the brakes so I can work with the minimum spindle size for incorporation into the IOS.
Note the dash penetrations, you will not get a look at many insights striped to this level.

Fix for the broken water pump pulley????

Fix for the broken water pump pulley????
Is it really fixed??
In a moment of cheapness, I decided to try and fix the water pump pulley, instead of buying a new one which comes with half the pump.
I glued the central metal core to the part of the pulley that was still intact, and after that dried, built up the rest of the pulley with epoxy putty. Since the AC and belt tensioner were also gone, I found some buna-N O-rings that fit nicely in the grooves of the motor output pulley and the water pump pulley. The pulley is not balanced, so it may shake apart? If I can get several minutes of run time, so I can see the condition of the rest of the system, I will be happy, and will break down and buy a new one.

Cool Transmission Cooler

Cool Transmission Cooler
Cool Cooler
The old radiator from the car was gone except for the short transmission cooler heat exchanger, so I snapped a few photos of the cooler tube.
It is a brass double wall tube, which maximizes the heat transfer, since the coolant passes inside and outside the tube, and the transmission fluid passes between the two walls. There is a lot of cool engineering in the Insight that is hidden away so we never get to see it.

The stand

Getting closer, the motor, exhaust, ECM,TCM,steering wheel, EPS,Dash display are all mounted. Still a lot to do before the first powerup. The rest of the demos construction will be picked up at;
UDHEV
The remains of BlueBird1 will wait until I get BlueBird2, and the two will be combined to make a Blue CVT Insight for my dear wife Sue.
The stand
exhaust,dash, steering

water pump innards

Have to get the water pump to run if the demo is to be a working engine, so I figured would take a closer look at the possibility of making it run off a 12 volt motor.The core metal of the pressed on pulley either needs to be removed with a special puller, or I need to machine a new plastic pulley. Will have to ponder that one, I don't want to brake it trying to pull off the rusted pulley.
Pump has thermostat and additional oil loop. Nice that it is all o ring seals.
water pump innards
Water pump explored

Trying to plug it all back in

Ok now that I have it all out, I have to try and reconnect everything if I will ever have any hope of getting the thing to work.
Thanks to Mike Saboe, I have the correct harness and CVT info so I can continue.
No playing pool for a few days.
Got the EPS rack off the car so that function is included. This is an interesting cross plug puzzle.
Trying to plug it all back in
An Insight on a pool table

Totally stripped

I got the rest of the stuff out of the car. The harness now has to be reconnected to everything before I forget where things went. I also found that the ABS control board cover was gone, and the PC board was damaged. Bummer!
Totally stripped
Finally down to the bare bones chassis

The Dash exposed

The Dash exposed
Ducting and under dash covers
Got the plastic covers on the dashboard removed. Was a bigger job than I figured.

An Insight on a stand part one IMA/CVT power plant

The engine IMA, and CVT on my work bench ready to be cleaned and mounted.
An Insight on a stand part one IMA/CVT power plant
The PowerPlant

Engine out With Brick's help

Brick came up and helped me get the engine/tranny out of the Blue Bird
Engine out With Brick's help
Ready for MG2???

Red White & Blue

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Red White & Blue
The three Insights take their positions.

Wiring harness

Wiring harness
The spinal column of the Insight
Pulled all the wires out from under the hood, pretty long harness.

CVT valve body

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Valve body
Had the cover off for welding so I snapped a shot. Valve body.

Behind the seat

You can't see in here without removing lots of stuff.Left to right,Gas fill tube inlet, IMA battery air inlet,Power Inverter air inlet, and IMA 3 phase drive wires.
Behind the seat
Stuff you dont see

The tinsy front end

This is what the actual working suspension looks like with all of the body removed? looks like a motorcycle.
The tinsy front end
Thats All There Is

Stuff needing replacement

Stuff needing replacement
Broken Stuff
Water pump ,Intake manifold, Air filter box, tensioner mount, CVT bottom cover

Something is missing

Looks pretty bad, hope I can get it to run.
Something is missing
Pretty bad

Pit ready

Pit ready
The Pit is ready
Got my repair pit ready for some action.

Yikes there are parts on the ground

No radiators, fan dragging hood will never close properly, fenders gone,three blown tires, what did I get my self into?
Yikes there are parts on the ground
Yikes Stuff dragging on the ground