I agree at some point it would be better, not likely cheaper though IMO.
I don't think we are there yet for me for several reasons.
1) I like tinkering with the oem system and learning more about it (Useful for me and others to have a growing understanding of how it all works) It also means others can follow in your footsteps without making major changes if they want, and it retains the Insight heart...
2) A bespoke BMS and motor driver is unlikely to be cheap, the capacitor cost aside this hasn't cost much so far. I'm using cheapo balancer boards, cheap led driver charger etc. You might have mentioned it but how much is the Motec dash/ecu stuff? Plus I have loads of spares, so if I blow the motor/driver/mcm etc I can replace it for very little.
3) If you replace the BCM/MCM stuff at the back you then have to fake signals to fool the ECM at the front
. Doable but you are just moving the faking from one part to another unless you also replace the ECM and go down your route..
I'm learning a lot doing this project and supercaps in a road car is pretty radical.
I don't know much about the Insight but I do know electronic car modification.
The approach that you're taking (ie intercepting, fooling signals, etc) was the most common approach to modification of car electronic systems about 15 years ago. I always enjoyed this approach, and did a lot of it. In fact, for some car systems where (a)the software is not hacked and so aftermarket software is not available, or (b) the systems are those that very few people modify (like stability control, electric power steering, etc) this is still the best approach.
However, where there are commercially produced products that can take over the function of the factory system that is being fairly crudely hacked, then the results are invariably better going with a new system. Basically, when you're
in charge of the logic, then you can do things the best way for the new requirements, rather than modifying the factory way.
Since these days there are aftermarket electric car motor controllers, and aftermarket battery management systems, all with their own software, there comes a point where intercepting the factory system will no longer be the best way of doing things.
I admire what you are doing, but hacks on top of hacks almost always end up with unwanted outcomes, or less than optimal outcomes. You're in the best place to make that judgement, but don't lose sight of the bigger picture of what is available to do what you're doing, starting from the idea of what you actually want to achieve
- rather than how can I make the factory system achieve what I want it to achieve?
The MoTeC ECU and dash were expensive (although I bought both second-hand, so saved about 50 per cent) but engine ECUs and dashes to achieve much the same outcome are available for - say - 1000 UK pounds total.
Unfortunately, none of you get to drive my car but I'd be confident in saying that you'd all be quite astonished at what has been achieved - specially in areas the factory ECU system is pretty limited...lean cruise, EGR, idle smoothness, outright turbo power. Until you have full control over everything you don't realise how emancipating it is - and you wonder why you didn't do it sooner.
I repeat: I admire what you are doing (and have done), but as technology moves on, tweaking the Honda system is going to become increasingly a less-than-optimal approach.