EGR Gasket Reverse Engineering
2000-2006 HONDA INSIGHT 1.0L
2000-2006 HONDA INSIGHT 1.0L
The 2000-2006 (G1) Honda Insight was the first hybrid sold in the US, and one of the only cars to combine a manual transmission with a hybrid system. Due to its low production numbers (~17,000), replacement parts, new or aftermarket, are being discontinued at a high rate.
The EGR system on the Insight's 1.0L 3-Cylinder engine utilizes a unique aluminum plate to route the exhaust gas into the intake ports (see image to right). The small passages in the EGR plate are known to clog up with exhaust soot over time, requiring cleaning every 100,000 - 150,000 miles for optimal performance. When an EGR Plate cleaning is performed, or anytime the intake manifold is removed, the metal EGR plate gasket should be replaced. Therefore, when I found no OEM or aftermarket replacement options available for this gasket, I decided I would reverse engineer and create my own!
Project Requirements:
To have the same fit and function as the original Honda part
To be manufacturable at a 500-piece production volume for a reasonable cost
A Clogged G1 Honda Insight EGR Spacer Plate
Dec 2025
The first step to recreating anything is measuring it and representing those measurements digitally. This can be accomplished by manual measurement, 3D Scanning, or, in this case, 2D Scanning. When the geometry being measured is flat, or along one plane, a 2D scanner (or in my case a printer's copying machine) does a fantastic job mapping the geometry on a digital image file like a .TIF or .JPG.
I simply placed the gasket into the copier and scanned it at 600 DPI (Dots Per Inch) on both sides. Sometimes, depending on the color of the gasket, a piece of black paper as the background should be used.Â
Jan 2026
The scanned image can then be imported as a canvas in Autodesk Fusion and used as a template to recreate the geometry in a sketch. Proper scaling is important, so ensure the image is scaled to the real-life gasket. After scaling, one of the bolt hole centers was aligned with the origin, and I traced all the cut shapes (outline, ports, bolt holes). After tracing the "blank" cut geometry, the embosses were created and the coating was added as a 0.01mm surface over the part for reference only.