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Old 08-13-2010, 07:43 AM   #2 (permalink)
Daox
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Location: Germantown, WI
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CM400E - '81 Honda CM400E
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To go 40 miles, lets estimate the average usage of 300Wh/mile, you need a pack capacity of 12kWh if you drain your batteries to 0% state of charge. To get this, you could use 12 12V batteries that have a capacity of ~83Ah. A group 27 battery would give this to you. However, you will be dishing out ~$90 a piece for these new, or $1080 plus tax. Thats almost half your budget.

Now, lets factor in the other things that really show how not easy this is. 40 miles is your range you want, but the above calculation shows us pushing the batteries way harder than they should be. Generally you don't want to go below 50% SOC to maintain decent battery life with lead acid batteries. So, now you need a $2200 battery pack and weighs twice as much (~63lb per battery, or 1500 lbs). This will honestly break the Metros back as its simply too much weight (this also assumes you can actually find a place to put 24 batteries in the car).

The alternative is to go with lithium batteries. They will allow you to get your 50 miles and highway speeds. However, the pack alone is going to cost you roughly 6X more. 45 3.2V (for 144V) 90ah lithium batteries will cost you $6075.
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