94 Geo MetroInstrumentsElectric Motor Mounted on TransmissionBattery Charger (120v)Rear SpringsNew Spring in PlaceBatteries in the BackCoupler
OwnerDean Holden
LocationSudbury, Massachusetts United States map
Email email image
Vehicle1994 Geo Metro
(SOLD - I don't own this anymore)
Purchased on 6/18/2009 with a blown engine.
The body and frame are in very good
condition considering it was 15 years old
MotorD&D Motor Systems, Inc. ES-31B Series Motor 90 HP Peak Series Wound DC
Drivetrain5 speed standard shift
ControllerCurtis 1221C (120 vdc / 400 amp)
Batteries10 Trojan 1275, 12.00 Volt, Lead-Acid, Flooded
Also an 11th T1275 battery for 12 volt
System Voltage120 Volts
ChargerQuick Charge 120 Volts (Smart Charger)
also a 12volt charger for the accessory
WebPage /> charge%20ON%20BOARD.htm
Heater1500W 120 Volt DC replacement for the stock
heater ( WebPage )+ a DC
Contactor to connect it to the 120V and
switch it with 12V (WebPage
Instrumentation50-150 VDC Volt Meter
0-500 Amp Meter (not working)
120v State-Of-Charge Gauge
Top Speed70 MPH (112 KPH)
AccelerationProbably like an ICE version of the Metro
Range45 Miles (72 Kilometers)
Less with stop and go traffic. I use it for
my daily 35 mile commute
Watt Hours/Mile415 Wh/Mile
I calculated this using 31 miles driving
distance with an average of 30mph and
12.85Kwh to charge it. It's costing me
about 4 cents per mile to drive it. I am
purchasing my electricity from a wind farm
at about 17 cents per KWh
EV Miles
Start:142,342 Miles (229,028 Kilometers)
Current:149,119 Miles (239,932 Kilometers)
Total:6,777 Miles (10,904 Kilometers)
Seating Capacity2 adults in the front, and two small people
in the back
Curb Weight2,700 Pounds (1,227 Kilograms)
estimate car ~ 1800lbs, batteries ~ 900lbs
Tires12" standard Geo Metro tires
Conversion TimeLost track, but I'm sure it was more than
200 hours including time wasted going down
the wrong paths...
Conversion CostAnticipating about $6550 (conversion kit
~$4600, car ~$200, vac pump ~$300, heater
~$150, springs ~$100, misc ~$1200) does not
include batteries (~$2000).
Additional FeaturesGast Vacuum pump and switch for brakes.
Front coil springs from a 98 Ford Ranger, shortened by about 3
inches and used in place of the rear springs
PLEASE NOTE: I purchased a 120V Geo "conversion kit" from
Wilderness EV, and would not recommend them to anyone. Their
customer service was very poor, but even worse the quality of
their custom parts is poor. I wasted many hours and dollars
making things right, and a year later am still fixing things.
Feel free to contact me for more information.

2009-11-22 Update: Took it for a short spin today, and it
worked. I still need to work out a number of kinks. Maybe
add new springs in the front and re-align the front wheels.

2010-03-14 Update: Took a break for a while due to cold
weather. Put the original axles back in it, and made a half-
circle cut in the frame to fit the motor. Got it up to 25mph
in my neighborhood.
2010-03-15 Update: Added vacuum pump, brakes feel much better
2010-03-16 Update: got car registered, drove it about 20
miles, got it up to 50mph.
2010-03-18 Update: got car inspected, drove it about 30
2010-04-26 Update: almost 700 miles on it. Using it to go to
work daily (~ mile round trip) Had to pull motor to adjust
coupler which was binding on the motor and causing lots of
vibration. I thought the transmission was going.
2010-05-11 Update: Celebrating my first 1000 miles!
2010-05-18 Update: had to replace the circuit board in the
quick charger because it was not working right. They were
very good about sending me a new one for free.
2010-06-13 Update: Celebrating 2000 miles of driving.
2010-11-24 Update: Had some problems with the coupler first,
then the motor blew up. I think it was damaged in shipping
and finally gave up. I have a new (rebuilt) motor from D&D
and I'm back on the road.
2011-07-19 Update: Had big problems with the adapter plate
purchased from Wilderness EV, it was off center and off true,
so I had to have it fixed at a cost of about twice what the
original plate cost me. Seems to be doing well now, though
I'm still not sure about the coupler because I'm having some
vibrations at higher RPMs.

code by jerry