The University of Wisconsin - Madison FutureCar Team has designed and built a lightweight, charge sustaining, parallel hybrid-electric vehicle for entry into the 1999 FutureCar Challenge. The base vehicle is a 1994 Mercury Sable Aluminum Intensive Vehicle (AIV), nicknamed the “Aluminum Cow,” weighing 1275 kg. The vehicle utilizes a high efficiency, Ford 1.8 liter, turbo-charged, direct-injection compression ignition engine. The goal is to achieve a combined FTP cycle fuel economy of 23.9 km/L (56 mpg) with California ULEV emissions levels while maintaining the full passenger/cargo room, appearance, and feel of a full-size car. Strategies to reduce the overall vehicle weight are discussed in detail. Dynamometer and experimental testing is used to verify performance gains.