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Weekly Recap: GM plans massive new paint shop at Chevy Corvette factory

General Motors is laying out some serious green to maintain the Chevy Corvette's expansive color palette. The automaker is breaking ground on a new paint shop this summer that's part of a $439-million investment to upgrade the 34-year-old Bowling Green, KY, factory that builds the Stingray. The massive new structure will total 450,000 square feet, nearly half the size of the current 1-million square-foot facility. Construction is expected to take two years and won't impact Corvette production. The upgrades include new robots that save paint and create a better finish, longer, more efficient ovens to bake in the finish, and LED lighting. There's also a dry scrubbing booth technology with a limestone handling system that eliminates waste. GM has invested $135 million in the factory in last four years for the changeover to build the C7 and to relocate its Performance Build Center to Bowling Green. The improvements continue to modernize the Kentucky factory, which has become a tourist attraction in its own right, as more than 56,000 enthusiasts visited it last year. The upgrades are part of a $5.4-billion investment GM confirmed in April that will remake its US footprint in the next three years. The Bowling Green expansion underscores GM's continued commitment to the Corvette, which sold nearly 38,000 copies around the world last year, an eight-year high. "With this major technology investment, we can continue to exceed the expectations of sports car buyers for years to come," North American manufacturing manager Arvin Jones said in a statement. OTHER NEWS & NOTES Takata recall hits 34 million vehicles The National Highway Traffic Safety Administration expanded the Takata airbag recall to an almost unthinkable 34 million vehicles on Tuesday. The recall is part of an agreement reached by the two sides where Takata admitted some of its airbag inflators have a defect, and the deal compels the company to comply with all future regulatory actions and investigations. Takata's airbag inflators were produced with "a propellant that can degrade over time" and lead to ruptures, NHTSA said. Six deaths have been attributed to the flaw worldwide. Investigations conducted by Takata, automakers, and others have not determined the exact cause of the inflator problem, but NHTSA said moisture appears to alter the propellant's chemical structure. It then ignites too rapidly, creates too much pressure that ruptures the inflator, and blasts shards of metal at passengers.

It's possible to go 111 miles on electricity in the new Chevy Volt

Wayne Gerdes at CleanMPG put the 2016 Chevrolet Volt in Premiere trim through a few closely watched on-the-road tests over a few days. One of them was a run from full charge to EV-only exhaustion, and at the end of the trip Gerdes had traveled 111.0 indicated miles on a single charge, 111.9 according to his Garmin. What's the catch? He guessed his average speed was about 20 miles per hour, which was 15 and 20 mph around town and "a few miles" at 50 mph on the highway. The EPA says the new Volt should go 53 miles on battery power. In the 2011 Volt, rated at 38 electric miles, Gerdes got 75.5 miles on a charge. The upshot is that at urban driving at average speeds should get drivers the EPA rated 53 e-mpg without fuss. He wasn't so impressed with performance in Charge Sustaining Mode, though. During one run that covered 101.2 actual miles in CSM, using 1.691 gallons, the Volt got 59.8 mpg. Speaking of driving in CSM only, Gerdes said it's less efficient here than in competitors from Toyota, Honda, and Hyundai, but that's one of the few performance-related complaints he had. Elsewhere around the PHEV, Gerdes liked improvements to the eight-inch display and rear-view camera, build and design quality, the much quieter ride, and the switch to regular fuel. The six-foot Gerdes found the cabin space still cozy, especially in the back where ingress and egress could be a challenge for people of a certain stature. He lamented the fact that he couldn't find instantaneous fuel and energy consumption or among the many readouts, and would prefer the sedan kicked into glide mode sooner. In spite of that, he declares the Volt II "a full blown electric car." Head over to CleanMPG for the rest of his assessment.

Recharge Wrap-up: Ford HQ gets giant solar array, Chevy City Express gets 24 MPG city

Ford will be building Michigan's largest solar array at its Dearborn headquarters. With funding from DTE Energy, the solar carport will provide covered parking, as well 30 charging stations for electric vehicles. The array is expected to generate 1.13 million kWh per year for Ford's operations, and offset 794 metric tons of carbon emissions. Read more in the press release below. Chevrolet announced the fuel economy for the 2015 City Express, at 25 mpg combined. The cargo van is rated at 24 mpg in the city, and 26 mpg on the highway. Chevy credits the van's inline four-cylinder engine and continuously variable transmission for its impressive city mileage. For its customers - which are mainly businesses - "The fuel economy of the City Express will help stretch their dollar at the pump and give them the flexibility to invest the savings back into their business," says Chevrolet's Ed Peper. The City Express starts at $22,950. Read more in the press release below. Engineers at the University of Wisconsin have developed an efficient engine that runs on a diesel-gas blend. The engine, which uses a computer to control the blend proportions, is about 15 percent more efficient than the any diesel engine according to mechanical engineering professor Rolf Reitz. The team has put the experimental reactivity controlled compression ignition (RCCI) engine in a demonstration car - a 2009 Saturn. "This vehicle can do 50 miles per gallon," says Reitz, who believes the system could be improved further. Read more at Wisconsin Public Radio. The Southeast Alternative Fuel Conference and Expo will take place in October in Raleigh, North Carolina. Held at the NC Clean Energy Technology Center from October 22-24, the event will feature a variety of exhibitors, speakers and, most importantly, alternatively powered vehicles. "The three day conference will be a one-stop shop for fleet and transportation related decision makers to learn about return on investment, efficiency and alternative transportation fuels such as biodiesel, electricity, ethanol, propane and natural gas," says Anne Tazewell of the NC Clean Energy Technology Center. If you can't make it to Raleigh for the Expo, you can still enter to win a free two-year lease of a Nissan Leaf at the Center's website. Learn more about the event in the press release, below.