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.
Blue Insight arrives "Blue Bird"
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.
(Posted 11/18/2007 by mikey)
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.
(Posted 8/10/2007 by mikey)
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.
(Posted 5/2/2007 by highwater)
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.
exhaust,dash, steering
(Posted 3/13/2007 by mikey)
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 explored
(Posted 3/8/2007 by mikey)
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.
An Insight on a pool table
(Posted 3/7/2007 by mikey)
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!
Finally down to the bare bones chassis
(Posted 3/7/2007 by mikey)
The Dash exposed
Ducting and under dash covers
Got the plastic covers on the dashboard removed. Was a bigger job than I figured.
(Posted 3/5/2007 by mikey)
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.
The PowerPlant
(Posted 3/4/2007 by mikey)
Engine out With Brick's help
Brick came up and helped me get the engine/tranny out of the Blue Bird
Ready for MG2???
(Posted 3/4/2007 by mikey)
Red White & Blue
Red White & Blue
The three Insights take their positions.
(Posted 3/4/2007 by mikey)
Wiring harness
The spinal column of the Insight
Pulled all the wires out from under the hood, pretty long harness.
(Posted 3/4/2007 by mikey)
CVT valve body
Valve body
Had the cover off for welding so I snapped a shot. Valve body.
(Posted 3/4/2007 by mikey)
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.
Stuff you dont see
(Posted 3/4/2007 by mikey)
The tinsy front end
This is what the actual working suspension looks like with all of the body removed? looks like a motorcycle.
Thats All There Is
(Posted 3/4/2007 by mikey)
Stuff needing replacement
Broken Stuff
Water pump ,Intake manifold, Air filter box, tensioner mount, CVT bottom cover
(Posted 3/4/2007 by mikey)
Something is missing
Looks pretty bad, hope I can get it to run.
Pretty bad
(Posted 3/4/2007 by mikey)
Pit ready
The Pit is ready
Got my repair pit ready for some action.
(Posted 3/4/2007 by mikey)
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?
