I have one of Mike's chargers on order. There is no way I would connect a dumb charger to this complicated car and rely on myself to control it. There is just too much at stake. I feel very comfortable with Mike's design.
I think some are making much too big a deal out of removing the battery in order to do it right. People remove batteries every day. If you want to connect the dumb charger correctly you have to remove the battery as well.
So if you are willing to risk your battery with no control, and you are willing to risk your car and your safety with improper installation, go right ahead with a dumb charger. You might get away with it as others have.
I think some are making much too big a deal out of removing the battery in order to do it right. People remove batteries every day.
Those people have the technical ability, the facility, and the tools to remove the battery pack safely. Many Insight owners don't satisfy one or more of these requirements which makes installing a charger harness a legitimate "big deal".
I satisfy the first and last requirement but live in an apartment that prohibits working on one's car in the apartment carport. I have nowhere else where I could work on my car. I have been able to get by with doing work that's mostly inside the car (e.g., MIMA and Rostra cruise control installations). However, pulling the battery pack out would mean that I would need to place it on the carport floor which would certainly attract unwanted attention. I am hopeful that I might be able to merely raise the end of the battery pack where the connections must be made without removing the battery pack or maybe shift the battery pack enough to gain access without removing it, but this might be wishful thinking. This makes the charger harness installation a "biggish deal" for me. I am quite envious of those with great workshops, garages, etc., but I am not envious of the maintenance required by homes with such great facilities
The worst case for me would be that I am unable to install the new charger harness. In this case, I would just continue using my dumb charger with its positive lead spade connector as I have for 2 years, I would add the ability to run the battery pack cooling fan during charging, and I would sell my new charger. So I am luckier than some Insight owners who would face shortened battery pack life because they are unable to use a balancing charger due to the installation of the charger harness being a legitimate "big deal" for them.
Art,
I understand your situation, and will be providing the faston connector on your harness, with an extended + lead on the fuse assembly as you requested.
I am not saying you must remove the pack, only that you will find it much easier to do a clean install if you do.
Starting some time this month, I will hold weekly Saturday grid charger install meets, where you can join me for a day of insight fun,networking with other hybrid owners and get your charger installed and begin balancing your pack when you get home.
Lifters and extra hands will be available.
I also expect that garages in different parts of the country will offer a charger install service for the people uncomfortable doing it them self.
I see that AZ,Texas, CA, and a few other states have several people on the list, so local install gatherings may be another way to get some technical help.
Those people have the technical ability, the facility, and the tools to remove the battery pack safely. Many Insight owners don't satisfy one or more of these requirements which makes installing a charger harness a legitimate "big deal".
I satisfy the first and last requirement but live in an apartment that prohibits working on one's car in the apartment carport. I have nowhere else where I could work on my car. I have been able to get by with doing work that's mostly inside the car (e.g., MIMA and Rostra cruise control installations). However, pulling the battery pack out would mean that I would need to place it on the carport floor which would certainly attract unwanted attention. I am hopeful that I might be able to merely raise the end of the battery pack where the connections must be made without removing the battery pack or maybe shift the battery pack enough to gain access without removing it, but this might be wishful thinking. This makes the charger harness installation a "biggish deal" for me. I am quite envious of those with great workshops, garages, etc., but I am not envious of the maintenance required by homes with such great facilities
The worst case for me would be that I am unable to install the new charger harness. In this case, I would just continue using my dumb charger with its positive lead spade connector as I have for 2 years, I would add the ability to run the battery pack cooling fan during charging, and I would sell my new charger. So I am luckier than some Insight owners who would face shortened battery pack life because they are unable to use a balancing charger due to the installation of the charger harness being a legitimate "big deal" for them.
I don't know anything about refrigeration, so when my refrigerator breaks I have to pay somebody to fix it. I don't know anything about medicine, so when something goes wrong with me I have to pay a doctor to fix it. I DO know about cars, so I fix them myself. We all have different skills. Those who don't know about cars, or don't have a place to work on them, have to pay somebody else to fix it for them. There is a whole industry built around this! Possibly you could find somebody from a car club or something to help you.
But, since you already seem to have a wire connected to the right terminal that you're happy with, why not just splice into that wire and then install the rest of the easy stuff? I'd hate for you not to keep this great charger over something relatively trivial like maybe or maybe not having to remove the battery. There is always a way!
When mine gets here I will evaluate whether I can connect that terminal without removing the battery. If I don't have to remove it, I won't. Like you, I'm hoping to be able to move it around enough to get to the terminal. I'm having back problems right now, and there is no way I could remove the battery by myself.
I've recently lost my job, and I need to make some income until my next gig rolls in. I've built three chargers so far, one in my signature and two that were shipped out today.
The chargers are built using recycled computer power supplies for cases, and can be made custom if the person desires so. Note that this might incur extra cost, as I may need to buy and gut a perfectly working power supply, or buy an LED fan to give the preferred color, etc. Please reply here or drop me a PM if you are interested in this - there are many options.
I'm not an electrical engineer, but my charger has been running strong for many months, and is based on Mike Dabrowski's original 350ma design. It is superior to other chargers in the sense that it uses a fan for the charger itself, as well as powers the pack fan (which is very important if you're in a hot place like me). I also use Mean Well power supplies, and not cheap Chinese knock-offs.
This is essentially a pack balancer/overnight charger. It will take many hours to recharge a fully depleted battery, but has been ample for me, as it helped me pull 115MPG over 1200 miles for my daily 25 mile commute (when I had a commute ).
I'm selling 100% complete kits that will require no soldering. Connections to the HV battery are pre-made, including diodes and are fused. Additionally, an external fuse is used on the case for the AC side to allow for easy replacement if it is blown from a power surge (versus opening the case to replace). Connections to the fan are made via included splice terminals. As of the current design, the only tool you will need is a basic ratchet or wrench set (plus a torx driver to remove the battery box - I can help find if needed), and a tool to crimp four solderless wire connectors/two splice connectors. A multimeter is highly recommended, and can be included at a very low cost if necessary.
I've done the math, and if someone were to purchase all of the parts necessary, not including a power supply shell (case), it would cost $130 or more from Jameco.
For this run, I'm asking $250 USD, including shipping ($15-20) for the kit. These orders must be placed by October 15th, when I will be ordering the parts. A $100 deposit will be required to cover my investment in parts by that date, and forfeit if the buyer backs out and the charger is unable to be sold to another forum member.
As of now, all critical parts are in stock, but I will update if there will be any delays. I hope to place the order before the 15th, receive the power supplies, dedicate a "build day" once received, and ship them all out at once - for recept (knock on wood) by Halloween.
This is the cheapest that I'm aware of that a full kit has been sold for on this forum. I don't believe it will match Mike's upcoming $500 kits in fit and finish, but it will reliably charge and balance your battery!
Additionally, if anyone would like to buy a "do it yourself kit", I could arrange to send all necessary parts at a very reasonable price. It would require that the person have a power supply or other suitable case available, as well as a method to secure the power supplies. Only someone who is skilled in working with electronics should consider this. I'm willing to help as time permits, but may be in a new job before long. Post here or PM me if you're interested.
I will be making an instructional video on how to make the connections within the next few days, and I'll make sure to post it here. Honestly, the most difficult part should be taking off the stupid battery cover!
I will need to put together some kind of a liability waiver, as I cannot handle the financial burden of a lawsuit, just as Mike does with MIMA kits. If you are concerned about the safety of this type of charger, please ask questions here or read up in the forum.
Feel free to ask questions here, email me or drop a PM, if you prefer.
PS: An Insight II charger may be available shortly, depending on whether I can get into an Insight II trunk, or find reliable instructions. It would cost a little less, as it would require one less power supply. If one is brave enough to handle the connections themselves, I would be happy to build and configure just the charger itself.
Any kits available? I live in Southern California, and am interested in your kits. I know this is an old post, but perhaps you are making some more? Or have one you have not sold? Let me know, thanks!
David
424 744 9600
I don't know anything about refrigeration, so when my refrigerator breaks I have to pay somebody to fix it. I don't know anything about medicine, so when something goes wrong with me I have to pay a doctor to fix it. I DO know about cars, so I fix them myself. We all have different skills. Those who don't know about cars, or don't have a place to work on them, have to pay somebody else to fix it for them. There is a whole industry built around this! Possibly you could find somebody from a car club or something to help you.
But, since you already seem to have a wire connected to the right terminal that you're happy with, why not just splice into that wire and then install the rest of the easy stuff? I'd hate for you not to keep this great charger over something relatively trivial like maybe or maybe not having to remove the battery. There is always a way!
When mine gets here I will evaluate whether I can connect that terminal without removing the battery. If I don't have to remove it, I won't. Like you, I'm hoping to be able to move it around enough to get to the terminal. I'm having back problems right now, and there is no way I could remove the battery by myself.
Sam
I had three different Insights (two belonging to friends) that I wanted to charge (and hopefully after Saturday this week I will have Insight #2 here) so I asked Mike about buying test leads to go with his charger harness. They work great, and I don't remove the battery. However, I still get to take advantage of all the work and effort he put into the programming of his charger, which I would not have otherwise.
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