Project: The AeroMetro

[HydroJim]

I've been over on geometroforum.com for a few months now planning out the mechanical aspects of my project, but now that I've settled on a plan and put all my orders in online, I figured I would start a thread over here to document my work.

The goal of my project is to modify a 1993 Geo Metro XFi so that it capable of 100 MPG.

How am I going to do that you ask?

Well, here are the main contributors to my goal:

• turning the Metro into a 3 wheeled reverse trike. This will drastically cut weight and allow the vehicle to be more aerodynamic.
• Full streamlining. Shooting for a .16 Cd
• Megasquirt ECU for full fuel control
• Engine parasitic loss modifications

Those are the main points of my project.

Here are some pictures to help you visualize the plan:

[HydroJim]

I received my first parts in the mail recently and I have a lot more on the way:

Lightweight flywheel from a Suzuki G13 engine. Along with the clutch disk and pressure plate, the whole rotating assembly is 1.4 lbs lighter than the assembly from a G10 and it gives more clutch area for slower wear and a stronger feel.


Stainless Steel Engine fastener kit. Everything is there except the manifold studs. This doesn't really help economy, but it's a nice thing to have for my engine rebuild.

[Sven7]

Interesting project. Is that photo of your car or an example from someone else?

Any reason you're going for four tail lights? Seems you could use two LED trailer lights and keep the wake smaller. The kit I used on the Probe was $40.

[brucepick]

With three wheels, it likely will legally be a motorcycle when you're done.

[HydroJim]

Sven7- the photo is of someone elses car. I just like most of what the did so I'm basing mine off of that one. and my drawings are just rough ideas. I'll probably end up with a rear end similar to that of the Edison2 VLC

brucepick- It will have to be since I'm not going to have a bumper anymore!

[Frank Lee]

It will be interesting to see how it all comes out. About 15 years ago I wanted to do that with my Tempo but never got around to it...

[AndrzejM]

Interesting project. Subcribing to not miss any part of it.

[MetroMPG]

Your XFi is already capable of 100 MPG.

I assume you're talking about hitting the magic number with steady speed cruising. Any specific target speed in mind?

You'll be wanting some taller gearing too, I imagine.

[albyneau]

Originally Posted by HydroJim

I received my first parts in the mail recently and I have a lot more on the way:

Stainless Steel Engine fastener kit. Everything is there except the manifold studs. This doesn't really help economy, but it's a nice thing to have for my engine rebuild.

Things look to be shaping up (pun intended) nicely for you Jim~ BUT...

Keep in mind that unless you buy from a specialty manufacturer (like ARP) over-the-counter stainless hardware is the SAE equivalent of grade 2 steel, and NOT recommended for any torqued or load-bearing responsibilities.
Valve cover bolts- okay
Bumper bolts- iffy at best, and not if towing/being towed
alternator/motormount/etc- no way~ at least not in my book!

As far as your exhaust manifolds are concerned~ best to use stock or other good quality steel, Loctite in the head, and coat with an anti-seize compound on the manifold side...

Peace~
Scott

[HydroJim]

MetroMPG- steady state at 60 mph. so 100 at 60. I wouldn't mind taller gearing, but the transmission that is in there is the 2nd tallest and it's working so I'll keep it in there for the time being. 3.52 are hard to find around here and i don't have the money. I could get bigger wheels, but I'm going to stick with the 12 inch stock wheels in the front for now until I get back to work. Baseball season is fun, but not working sucks...

albyneau- Thank you for the concern scott, but this isn't just any stainless hardware. it was specially put together by a member on the geometroforums so everything is all spec'd out correctly. headbolts aren't part of the kit though so I'll be using some head bolts from a guy named "Geo Glenn"