[minic6]

I was asked to share some of the pics. and update info on my 94 Geo Metro.
I bought this car with only 2200 miles in 95. I now have 120,000+. It has been a great car for commuting. Fuel economy has increased from 40mpg (mouse nest in air cleaner). To about 44 to 48 driving as a non hypermiler. My 90 day average now is 62 mpg. 8/30/08

Before we start Yes a lot of the mods. added weight, but with 20 miles of my commute at a constant 55 and the last 10 rural it doesn't effect it that much. Once you are up to speed weight is not that big of a factor. Plus it isn't that much. Car will be weighed when completed. I hope to keep it about the same as a stock metro. I work for GM Powertrain in the V8 car division. I prefer to work on Vettes. Lots of my ideas came from MPG dream cars.

Modifications

Mobil 1 syn. 40 psi in tires. Kill switch currently tied into coil. Back seat removed along with seat belts. Highway speed held to 55 coasting and killing the ign. when possible. With my commute coasting is 6 of my 60 mile round trip. 14" tires and wheels, should now have 3.51 final drive, instead of 4.10. Installed along with 96 frt struts complete with vented rotors. These also provided 12 mm studs, drilled existing rear drums for 12mm studs. Lowered car by cutting coils.All tail light bulbs updated to led. Not so much for fuel savings but visibility for safety. Bonneville style hupcaps. Lowered springs by cutting. Installed vacuum gauge. Not as useful as hoped for, with 3 cyl. your into the power band most of the time. Not recommended, just use a normal light foot. Cool if you like the science look. Bumped up timing 3 degrees, no knocks.

Began aero updates right side July 07 Stopped August 23rd due to a problem with my leg. It cost me the rest of the warm weather.

First 2 pictures shows stock body work.

I chose to close the gap between the tires and wheel well. This was a learning curve as over the year since the spring cut, the car settled. Glad I had not finished painting it! After a retrim the tire can still contact if a corner is cut to sharp, but it is liveable as is. Note the use of duct tape, BAD idea it reacts with the fiberglass. Use blue painters tape instead.

The 4th pic. shows how the rocker was boxed after the rust was repaired . This gave me a platform to build my aero aids. One note 5th pic, if you use pink foam, coat it with a layer of bondo first as the fiberglass attacks it if you don't.
When the drivers side is started another idea may be tried.