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You might also want to slap a heatsink on the DC/DC.
I have a very small 100 watt converter on my motorycycle. Another EVer was shocked that I hadn't fried it yet. I think the fact that it's an open air vehicle has saved me so far.
That, and a motorcycle only has one headlight, but a Metro has two!
Run the DC/DC for a while with the heatlights on and feel how warm the thing gets.
How are you connecting the converter to the battery? What are you doing to power it up? (Turns on with key? etc.)
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