This is another custom piece for the Insight 1G. If you're a mechanically oriented individual you're probably wondering about overall dimensions and how they affect power train (engine/transmission) installation. The overall length of the 1.2L TDI and Insight engine were nearly the same at approximately 15 inches from the back of the engine block to the front most item on the engine. However, we increased the overall length of the 1.2L TDI by approximately an 1.4 inches as a result of the electric motor adapter.
We couldn't have used the original 1.2L TDI front engine mount anyway (the other two mounts we don't have to worry about since they are on the original transmission which we're using). It's made out of cast aluminum, set at a 12 degree angle for the Lupo, and can't be easily modified because of the way in which the aluminum was cast (tons of webbing to lighten the part while at the same time retaining strength).
So, we wanted a way to make a mount quickly with minimal machining and which would be somewhat adjusted during mock-up so we could make the mount on site. The best option turned out to be an aircraft style tubular engine mount. Working with tubing and sheet stock we mocked up and welded together a custom mount. Pictures to follow of the fabrication process and final product. Stay tuned.
