Ben Nelson's Electro-Metro Build thread

[bennelson]

Finally got a little bit of a break from work.

I started stripping the Metro this morning! Yea!

Expect to see photos and really bad YouTube videos sometime soon!

[bennelson]

This morning I had a few hours I could use to work on the Metro EV.

I first worked on the radiator, figuring that it was in front and the first thing I should do is make some space for me to work by removing it.

The radiator came out pretty quick and easy. It really was just disconnecting a few hoses and turning out some screws. Nothing was terribly rusted in or required cutting off. In case you were wondering, a Geo Metro holds exactly one coffee can's worth of coolant.

Then I started on the exhaust system. Not the same there. The middle connection of the exhaust actually did just unbolt. The muffler wasn't going anywhere though. I did end up having to cut that off.

I tried removing the right rear tire to make room for working on the muffler. To my suprise, nothing happened after taking all the lug nuts off! The tire is still stiffly attached to the hub! What's keeping it on there? I did spray some PB Blaster in and around the lug threads. I will look again tomorrow to see if anything loosened up.

Speaking of impossible to remove, how does a person take out exhaust manifold bolts!?!? I PB Blasted the heck out of them and tried using a breaker bar. Still won't move! Tell me there is nothing crazy like they are left-hand thread or something.

The photo at the top shows the parts that I got off the car so far. Not in the photo, but also surgically removed and available for resale is the pine tree air freshener that was hanging on the mirror.

I also stopped at the photography store today and bought a clamp that will let me mount my video camera to the wall near the car. This will facilitate some sort of "video log" of my project.

Expect to see some sort of videos in the future. Most likely time lapse of me cursing at trying to remove the gas tank. (please see my Dodge Shadow Gas Tank Rant)

[MetroMPG]

Originally Posted by bennelson

I tried removing the right rear tire to make room for working on the muffler. To my suprise, nothing happened after taking all the lug nuts off! The tire is still stiffly attached to the hub! What's keeping it on there?

Rust! I remember this happened to Firefly #1. Lots of WD40 (PB blaster or whatever you use), lay a piece of wood on the outer rim & pound away with a hammer. Or heat it up with a torch - I think that's what I ended up doing.

Tell me there is nothing crazy like they are left-hand thread or something.

There is nothing crazy like left-handed threads. Just corrosion!

[Daox]

Impact wrenches do wonders for corroded bolts (that are big enough to handle the torque).

[metroschultz]

Break the bolts.
You are not saving them anyway.
Or buy the cool rusted bolt removing sockets @ Sears.

http://www.sears.com/shc/s/p_10153_1...+Taps+%26+Dies

They are good to have and do a fantastic job.
The harder you tirn the tighter they bite.
Have Fun.
S.

[Ryland]

have you thought about posting a criagslist ad for selling metro parts? also remember that the catolitic converter has a high scrap value, so don't just toss it.

[bennelson]

I got the gas tank off today!

Just my luck, the one car I buy specifically to NOT USE GAS comes with a full tank!

Had to pull out two jerry cans to empty it! I also now own one gasoline-soaked sweatshirt.

I worked on the exhaust some more. I got the one bolt off with help of a five-pound section of steel pipe extending my breaker-bar. The other bolt snapped right off with help of the same "pipe-wrench".

But wait! What's this odd connector just past the catalytic converter? That's rusted on too, and now the pipe isn't even connected to anything for me to wrench against!

Curses! More PB Blaster....

I am starting to get a pile of parts I no longer need. I was going to ask what the best place to sell them is. Is anyone here looking for Metro parts? Should I try TeamSwift, or just Craigslist?

So far, I have the radiator and fan, entire exhaust system w/ hangers, gas tank w/ fuel pump, filler tube, etc.

Glad to be rid of all that gasoline. It is nasty/smelly/flammable.

Need to air out the garage, so I can get the propane heater going again.

[bennelson]

You know it's not an official Electric Vehicle until there is a power plug sticking out the gas cap.

I couldn't resist.

Here it is.

[Daox]

Originally Posted by bennelson

Glad to be rid of all that gasoline. It is nasty/smelly/flammable.

Need to air out the garage, so I can get the propane heater going again.

Where you see a problem, I see a solution. Lets just rearrange a few words...

Need to get the propane heater going again, so I can get a new garage.

Presto chango, no more being able to see through your garage walls.

[MetroMPG]

Haha. Nice plug.

I've had good luck with teamswift. Sold all of my parts through it: engine, gas tank, radiator, misc other stuff.