- Honda Car Owner's Manual

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24
ALUMINUMCONSTRUCTION
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The Honda Insight's body is made of aluminum,
offeringlightweightandahighlevelofbodyrigidityto
enhance overall fuel economy, handling and passenger
safety.
Aluminumweighsonlyone-thirdasmuchassteel.In
addition, aluminum alloy is highly versatile and readily
lendsitselftoawidevarietyofmanufacturingtechniques.
Lastly, aluminum is extensively recycled, which helps
loweritscost.TheInsight'saluminumbodyinwhite(just
thesheet metal:doors,hood, etc.)is roughly40 percent
lighterthanacomparablesteelbody.
Thebasicstructureisanew,lightweightaluminummonocoque,reinforcedinkeyareaswithaluminum
extrusionsjoinedatcastaluminumlugs.Stampedaluminumpanelsareweldedontothisstructuretoform
anextremelylightandrigidplatformforthedrivetrainandsuspension.
Theresultingbodystructurehas13percentmorebendingstrengthandanimpressive38percentmore
torsionalrigiditythanacomparably-sizedsteelbody,despiteweighing40percentless.Theunit-bodypart
of the Insight'sbodyuses stressed sheet-metalpanels to absorb and distribute structural and suspension
loads,muchlikeanordinarysteelunitbody.
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Fromtheir experience building the AcuraNSX - the world'smostproduced aluminum-bodiedcar -
Honda engineershavegained extensiveknowledgeofaluminum.However,the Insightisdesignedfora
verydifferentpurpose.
Market requirements dictated the development of new, more cost-effective techniques for
manufacturingtheInsight'saluminumbody.Inresponsetothischallenge,Hondaengineersdevelopedthe
Insight'sinnovativeunit-body/space-frameconstruction.
The unit-body part of the Insight's body uses stressed sheet-metal panels to absorb and distribute
structuralandsuspensionloads,muchlikeanordinarysteelunitbody.However,withtheInsight'sbodyall
of these panels, includingthe roof, floor, front and rear wheel wells, rear quarter-panels, bulkhead,and
eventhedoorsandhood,aremadeofaluminumalloy.Thesestressedpanelsarereinforcedinkeyareasby
aluminum-alloyframemembers.
Itisthesealuminumframemembersandtheircast-aluminumconnectingjointsthatmaketheInsight's
hybridbodysounique.Inasteelunitbody,framemembersareformedbystampinginlargepressesand
thenjoinedtothe bodybywelding.However,the Insightusesextrudedframe members. Extrusionsare
drawnfromadieinmuchthesamewaythattubingismade,andliketubingareofconstantcrosssection.
Once formed, extrusions can be easily made into complex three-dimensional pieces, such as a curved
windshieldframe.Theyalsodonotrequireanyadditionalmachiningorfinishingaftertheyareformed.