Modified Cakley Muffler Mod, Edit 7/5/4

[cakley]

nice pics. would be great for others if you could photoshop them and label the input and exit pipes. That would really show how restictive the muffler is.

I never cut mine open, too scared!

[Jackmpg]

Hi Cakley,
Sorry, don't have much experience with photoshop or the like. Did
follow your prompt and gave a better description in the reply that has
the link to the pics. Hope that helps. Have the '00 back up on blocks
now (did turnpike testing this wkend) and getting ready for the 2nd tail
pipe. I remember you sharing somewhere about how to remove the
rear bumper, could you give explaination or share the link. I have the
service manual but from my experience hands on knowledge as yours
is invaluable. I guess a little improvement can lead to so many new
questions.
Thanks, Jack

[joecvt]

I did the internal version of the modification with yet another modification.
Instead of cutting through the pipe taking a chunk of pipe out, I drilled two
large holes (about .75 inches) into the same area. My only fear of cutting
all of the pipe off was that there would be no internal strength supporting
the tail pipe to the end. I know it doesn't weigh too much but as time goes
by and the exhaust gets old, the tail pipe may become loose before its
time.

JoeCVT

[Jackmpg]

I thought the same about tail pipe support. After mod completed I
observed the tail at idle for excess vibration movement. Fortunately
it just moved the same as the muff so I went ahead and posted the
mod. Noticed the weld support for the tail at the rear of muff is very
strong and the tail is short and light or I wouldn't have cut all the
way thru.
The holes you cut should be big enough to do the job. Would really
like to know what results you have observed so far. How's
accelleration and highway mpg's?
Will be working on 2nd tail soon. Did WeatherTech in chanel
window shade mod 1st (completed today). Lot's of rain here and
was tired of my left leg getting soaked if I cracked the window.
Will post the pics with the mod soon then finish the tail.
Thanks, Jack Lee

[joecvt]

I did not notice any major difference in acceleration although I got to
believe that it should help a little. What I did notice is that I can get
higher MPG without trying as hard and it seems like I don't have to push
the gas pedal down as far on some hills (till they get too steep)... If I
had to do it again, I probably would drill 3 or 4 holes just to make sure
that there was better exhaust flow. I was getting a little nervous about
noise level so I only did two but they are pretty big. I used the JB Weld
that takes 4 hours to dry and I did it in two stages so I had to wait over
8 hours before I could start it up and check for leaks and noise. I could
not tell any difference in noise level before and after. I think noise level
equipment would detect some slight difference but not enough for a
before and after human ear test.

After reading your post I went to the WeatherTech site but I did not see
a WeatherFlector for the Insight (I did see ones for other Honda models).
Did you buy another model and modify it?... I did try one that others
have installed (modified Civic 2 door 92602) but it didn't bend well to fit
the contour of the Insight window frame. All I can say is that they use
good adhesive because it took a long time to get the glue from the sticky
tape off the door frame. Plus, it looked too big for the window. I'm
looking forward to seeing the pics of yours...Could you also post the
part number that you ordered?

Thanks,
JoeCVT

[Jackmpg]

Hi Joe,
The part number I ordered was for a Honda Civic '96 thru '00,
2 door dx or hatchback ( pn=70046 ). It was a devil to make
fit but after I did the first door (5 hours) the second door took
about 45 minutes. Basically cut 1" vertical off rear of Weather
Flector and cut another 1/4" further but left tab to stick and
hold flector in rear of chanel. Cut 1/2" off bottom of front.
Also, cut lenth of flector so it wouldn't hang down more than 2"
( to remove some stiffness so it would flex to fit window chanel).
When installing must still hand fit (chanels vary slightly) and it's
got to be REAL tight to cause flector to follow chanel. If you
should cut too much you can shim (use material you cut off)
under front bottom where it won't be noticed. Finished
product looks good, like it was made for the car.
Just the same I found a car today that may make a better fit.
Dodge avenger, as soon as I get a chance to match my template
(made one that is within .010") against one I'll let you know.
Though it's been my luck so far that if it's a close fit for an insight
they don't make a window shade for it.
Hope this helps,
Jack Lee

[joecvt]

Thanks for the info Jack, Sounds like alot of work...I may wait a bit longer
to see if there is anything closer or maybe someday there will be one
made for the Insight...(I may be dreaming here).

By the way...My real name is John but I created the account as just any
other CVT owner (kind of like "Joe Millionaire" or "Average Joe").

JoeCVT

[Jackmpg]

Hi John,
I know we're off topic here but I wanted
to follow thru for you, and will post the
window vent mod in it's separate mod as it
should be soon. Been real busy going to dealer-
ships and parking lots with my window chanel
template checking you know what. Very
exciting. You show up at a dealer with what
looks like a giant flat banana in your hand
holding it up to various cars and sales people
and security are on you in a minute. And the
sales people will never believe you won't buy
a car, they just don't give up.
Anyway, I've found it. Best quality, WeatherTech
for a '04 Honda Accord 2 dr Coupe, pn 70321,
in chanel Weather Flector. Near plug 'n play. Will
need a heat gun to make p'np. You can use heat
gun for other projects later, Home Depo has them
for $30 to $59. You may want to wait for further
info before beginning, I'm practicing with my
existing vents now for the best way to procede
w/o destroying them but it really looks great.
Sorry you havn't heard from me in a while but
I've actually been chasing cars that look like
possible vents for the insight. I can now know a
year, make and model by looking at drivers
windows.
Found a few dead ringers, Mitsubitshi Eclipse,
Acura Integra ('01), Toyota Celica 2 dr coupe GT,
Nissan 300zx ('96), but the god of insights will not
let anybody make a vent for them under eternal
purgatory.
I have time to practice since the vents will not
arrive till the end of next week (end of Aug). Will
start on them as soon as I get them. Good News
and their OEM or better quality.
Jack
P.S. Will continue with second tail pipe mod as
soon as this vent mod is done. Vent mod will
keep the summer rains out.

[joecvt]

Hello Jack,

Thats a great idea using a template of the insight with other vehicles.
If only the Insight had higher production numbers we would be able
to order parts like any other car. We could probably be able to order
cut-out rear wheel skirts to expose the rear wheels. It looks like it
would be possible to have a look like this: (center image). I'll be
waiting a long time before I find a cheap set of skirts to play with.

Thanks for the ventshade update and I look forward to seeing the
installation results.

JoeCVT

[Jackmpg]

Hi John,
Will post mod for the window vent shade "WeatherFlectors" this
weekend if possible. Will not post here, will post as a new mod
as should. They arrived today, found them on the front porch
after work. Took less than an hour each to install them, as
mentioned they must be hand fitted since every window chanel
varies a little. So you cut a little less than needed, file a little,
file a little... Needed to use the heat gun to change the angle of
the front leg about 10 degrees. Not bad, very little work and the
result is beauty, they compliment the vehicle besides keeping the
rain out. They will not fall out but can be removed and reinserted
for whatever reason. Will post pic's of install, finished product and
will leave email or such for anyone with questions about mod so
they don't have to worry about damaging their new buy unless
they really goofed up ( I goof up from time to time too ). They
really look good, OEM or better.
Jack