I have installed several Enginer systems including the 2kwh kit in my Insight.
Enginer and I worked together on the prototypes, including fabricating a metal plate for mounting the cells. At the time we used Thundersky cells.
There are a few oddities that go along with putting a PHEV system like Enginer's in a Gen 1 Insight. So be careful.
That said, having a PHEV system in an Insight is fun!
Answers to your questions.
1) Your converter may not allow you to go down far enough. Usually Enginer had to do the setting "at the factory" to make sure it went low enough. I may have a 5000w one with the correct voltage for ~$600. Can you email me a pic to firstname.lastname@example.org
, then I can see which one you have. Specifically I want to see the bullet connectors, side view, end views, and other connectors.
2) You can always split up the pack. Not that hard, but just need to go slow and be careful. But they aren't really too heavy for the car. I assume you have RealForce cells in "sealed" metal boxes with big anderson connectors on them, right?
3) You can split them up and as a replacement for the nimh pack. No one has done it yet, but it sure is tempting.
I'm not sure of the status of MIMA at this time. Check in with 99mpg.com. I may have one coming for sale soon from a customer that I am removing it out of a car he is selling. I'll let you know.