Ryanthegreat1

What does your oil pan clearance look like? That engine is sitting LOW! I have a K24 sitting in mine and no way will the battery box mount clear the valve cover. I know the K24 is taller but on 13mm taller. Must be using the Hasport mounts? I heard they were crazy low.

Send a picture of your CV joint to lower control arm clearance as well.

Ryanthegreat1

I have my valve cover sitting proud of the strut towers. Oil pan only sits 1.5" lower than the Insight's original oil pan.

SpoolinAWD

It does sit very low. I thought that was because the innovative mounts are trash. I have the mounts for an auto chassis and a k20. Everyone complains about the mounts so I thought they are all sitting like this.

Ryanthegreat1

That is crazy low, the whole oil pan nearly sits below the bumper.

Here is how mine is tucked up. The bottom of the splash shield is where the bottom of the Insight pan was and in the back ground you can make out another sheet of plywood the oil pan is sitting on that is 1/2" thick.



And here is my half shaft clearance before going up another 1/2".



What is everyone running for halfshafts? EP3 Civic stuff was too long. Went to 94-01 Integra stuff. Still need to find a K20 intermediate shaft, I hear they are shorter.

Ryanthegreat1

Did an overlay of those Innovative mounts VS what I am doing. Crank is way higher and more rearward.

SpoolinAWD

I worked on the front suspension last night. I am using the ep3 struts, axles, spindles, and brakes. I have welded the insight ball joint insert into the ep3 spindle. I am not happy with the axles. The passenger Axle seems about 1/2 inch short. The driver side is about 1/2" too long. Back to the drawing board.

Ryanthegreat1

I ended up with a 94-01 Integra manual right shaft on the left and an 06-11 Civic 1.8 manual right shaft for the right. Had to steal an ABS tone ring to put on the Civic shaft. I will know for 100% sure if the Civic shaft fits on Thursday.

Got my left and right mounts built. Need to make a rear mount, not so easy with the TSX trans, it does not have the threaded mount lugs on the differential case.

Here is what I did about the ball joint situation. Note: I will be using the Insight flanged ball joint nut to fully capture my pressed in sleeve between the lip in the top of the sleeve and the flange on the castle nut.




Some steel inserts. For those wondering the taper is 7 degrees.



Bore out the lower control arms.

Ryanthegreat1

Oh hey, just noticed, I think your knuckles are swapped left and right. Insight has the front caliper on the front side of the rotors.

Huh, Civics were caliper on the rear of the rotor. Well.... I guess it could go either way. I do have a slight amount of toe out with the civic knuckles swapped left to right to put the caliper on the front. I wonder if that goes away or is less if I swap them. Also wondering if that changes any of the antidive in the suspension geometry by changing where the caliper mounts.

Edit2: Does not seem to matter where the caliper is located as far as the suspension is concerned, all that loading is sorted out in the hub, bearing, knuckle. The suspension just sees a torque on the knuckle no matter where the caliper is bolted. Sounds like it is packaging and getting the weight as central as possible. Guess I will move my calipers to the rear if the brake lines reach?

SpoolinAWD

I swapped the knuckles side to side and am now trying to figure out axles. The ep3 axles do not work. The passenger Axle is too short and driver Axle too long.

Ryanthegreat1

Are those shafts fully compressed? That is how they are measured on the spec sheets when looking at ordering them. If you stand them upright with the tripod joint at the bottom and then measure that seems to be accurate. The weight of the shaft will compress the tripod end.

The 05-11 passenger side shaft works in my application, just wish I could find something with an ABS ring. That generation the ABS tone ring is in the hub bearing. The compressed length is 23" and I am getting about 25mm of plunge before bottoming when installed at ride height. GKN bearings says all their tripod joints are 50mm plunge, that is the only documentation I could find.

I think I am going to leave my calipers on the front of the knuckle. This puts the brake line and abs sensor on the correct sides. No huge benefit to moving the caliper to the rear of the knuckle.

SpoolinAWD

I briefly measured the axles yesterday standing vertical and came up with 22.25" and 24". I also purchased a pair of integra gsr axles to play with and compare but bad weather hasn't allowed me to work on the car.

Ryanthegreat1

So my theory about buying non-ABS halfshafts and swapping the outer joint to one with an ABS tone ring won't work. Cheap shafts are not designed to be rebuilt, there is no chamfer on the splines to allow the snap ring to compress and release the outer joint. Cut one apart to confirm. Very annoying.



I took measurements on my setup. From differential face to inside hub face is 462mm and on the passenger side from tip of the intermediate shaft (K20) to inside hub face is 490mm.

And for those wondering the k24 shaft is 65mm longer than the K20 intermediate shaft.

Here is a picture for reference. The painted shaft is the K24 shaft.

Ryanthegreat1

I hear you on that one! 15 minutes here and there.

Ryanthegreat1

About that changing the shift arms on a TSX transmission to the RSX shift arms to reuse the Insight shifter.... Not possible, the aluminum housing for the arms has a completely different bolt pattern. Also the bolt holes for the RSX shift cable stay don't exist on the TSX transmission. She is a unique case.

In better news the TSX shifter box fits under the Insight center console just fine. Trim off the back corners and it fits like a glove. Just need to fabercobble a grommet for the TSX shift cables where they pass through the firewall.

Called up the Driveshaft Shop and had them make me some half shafts, should have those in a week or so.

Ryanthegreat1

Made some cover plates for the battery cooling holes.





Also did one for the power cables to the IMA but did not get a picture.

Ryanthegreat1

5.25" of ground clearance to the oil pan.

BongoBennie

I had these pressed into the stock control arm, going to try and press in Mugen compliance bushings if these wear quick,
https://www.kingmotorsports.com/p-43...t-inserts.aspx

They are for using Aluminum DC5 control arm with the used ball joint. Ive looked and cant seem to find the JDM knuckle that would in theory bolt up to the Insight.

Ryanthegreat1

I don't think the JDM DC5 had the ball joints in the lower arm like the Insight. I think why those sleeves exist is to make the JDM DC5 lower control arm fit the smaller ball joint on the RSX.

BongoBennie

Ahhhh, I get it.... I paid 250 in labor to have the guy remove balljoints machine and sleeve and it works great.... I am going to see about using either stock Type S compliance bushings or the Mugen solid rubber units ............. Since I have some attention, can I swap knuckles left for right? Insight calipers are in front and brake line will fit easy if so. (I wasn't clear on that from earlier in this thread)

Ryanthegreat1

That is what I did. Civic knuckles swapped left to right so the calipers are mounted on the leading edge. Just be sure to swap the calipers around so the bleed nipples are on the top side.

You will need an alignment after toes in pretty good but there is plenty of adjustment to correct it.

Not sure how you would swap the compliance bushings on the front control arm, I think they are vulcanized to the arm.

anno

Did you modify the Insight engine mounts?

Ryanthegreat1

The chassis side of the Insight mounts are original.

anno

Ok.

Any pictures?

Ryanthegreat1

My 2006 S2000 ECU arrives tomorrow. Can finally do some digging and figure out how to drive the MIL and engine temp gauge on a 2006+ S2000 cluster.

I have Arduino listening on the CAN bus to pull speed and rpm from the TSX ECU and display it correctly on an S2000 cluster.

Could probably pull the dash out at this point and graft in the TSX stuff.

BongoBennie

Question for the insight guys..... New stock shocks with Ground Control coil over kit OR Ksport EM2 complete coil over kit modded to fit, $500 bolt on vs $900 with mods. 150whp max.