1996 Geo Metro Aero Adventures
 

Hey everyone, I have been driving my Metro for sometime now and I'm going to start adding some Aero mods due to gas prices in our beautiful state of CA. I also did a partial rebuild on the motor, including new valves, new pistons, and other misc items. I did a photo shop of what I'm planning, I might go with an air dam on the front instead of the rounded nose in the photoshop. I just started the mock up with poster board before I start cutting aluminum. My goal is 80 MPG and I will be doing all the aero mods I can, any feedback is welcome, thanks!

Good start. Keep us up with the progress and savings that result.

Wheel Covers
 

I went with some cheap 14" pizza pans and secured them by drilling and tapping some screws, we will see how they hold up.

Gear ratio is a big factor in a Metro. There are four different ratios available. They range from 4.4 to 3.5 in 9% jumps. Obviously the big car with the small engine gets the 4.4 from the factory. As you slow the engine down you can advance the cam to gain low end torque. My high point was 54 mpg in a 95 sedan with a 1.0 and 3.8 gears. It had an Xfi clone cam and a +10 cam gear. Zero aero mods other than a grill block. The fun car got 44 mpg and was a 91 coupe with a 1.3 with 3.5 final.

I just started with an XFi. :) The biggest mod so far is making it a sedan delivery.

My concern with the pizza pans is they have no crown. With two fasteners, I predict they will 'taco' and lift on opposite edges.

You could easily drill and tap two more before it's too late.

With your boxed cavity, what would you do about the tail light area?

link to MetroMPG's Metro/Firefly aero
 

https://www.youtube.com/watch?v=1sQFtd-bTfwHere's a link to Darin's 'late model' Metro project, if you're unaware.
https://ecomodder.com/forum/showthre...irs-35164.html

i would check your local laws in regards to the extension of the rear might have to add a reflectors to it and side marker lights if it's more then 4 feet.. from the lights

Front Air Dam Mock Up......
 

Thanks to everyone for all the feedback, lots of good info out there. Got some aluminum in and started to mock up the front air dam, I will probably install a small splitter on the bottom to make it more rigid and give me something to rivet to. Question for you guys, I plan on doing an adjustable intake for summer/winter, how big should I make it? I know it is based on a lot of different factors, just wondering what size you guys run for a stock 3 cyl radiator. Thanks!

I dont think I will be building a very large cavity area, but if I do, my plan was to incorporate plexiglass for rear view mirror vision and taillight side view. More to come on the rear.

Think twice, cut once.

I don't have an example pic, but some air dams are just massive deflectors over the two front wheels; while other have been like what you show with a notch at the center bottom for a central jet. One, the other, or something in between? An added advantage is extrra clearance for gravel roads.

Another opportunity is on the sides where you could incorporate air curtains for the front wheels. Maybe the aluminum stands proud with an inner baffle wall terminating in a vertical slot. Stamped louvres would be cool.

For the splitter it will need to resist aerodynamic deformation. Look at the fasteners and their number for some idea.

https://ecomodder.com/forum/member-f...6-bedammed.jpg

And the thickness of the splitter. Overbuilt for your application, probably.

Does your Metro have little black wedges on the door window frames? Mine has one on the right [I just noticed], which lead me to two holes one the left frame 3/4" apart in exactly the right location for a peep mirror. With the convex inside mirror and two 2-3" outside mirrors I could remove the big, honking thing that won't fold back.
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How are the pizza pans doing?