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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.

Smaller Cars Endure Big Problems On Crash Test

In a crash test of 11 of the smallest cars on the market, only one vehicle received an acceptable rating. The rest received marginal or poor ratings in the study, providing evidence that supports a widely held notion that smaller cars are among the least safe on the road. No other vehicle group has performed as poorly on a new crash test than these mini cars, says the Insurance Institute for Highway Safety, the nonprofit group that conducted the testing. The latest results of which were released Wednesday. The Chevrolet Spark was the only car earning an overall "acceptable" rating on the small-front overlap test, and even that vehicle had its shortcomings, IIHS said. "Small lightweight vehicles have an inherent safety disadvantage," said Joe Nolan, the senior vice president for vehicle research at IIHS. "That's why it's even more important to choose one with the best occupant protection. Unfortunately, as a group, minicars aren't performing as well as other vehicle categories." The Mazda2, Kia Rio, Toyota Yaris and certain Ford Fiesta models all received "marginal" overall grades on the test, while the Mitsubishi Mirage, Nissan Versa, Toyota Prius C, Hyundai Accent, Fiat 500 and Honda Fit all earned "poor" ratings. Results from these sub-compact cars fare much worse than vehicles sized just a little bit bigger, IIHS said. Among 17 cars evaluated in the small category, five earned "good" ratings and five more earned "acceptable." Only introduced a year ago, the small-front overlap test has quickly become a key indicator of differences in automotive safety. IIHS introduced it as a way to replicate what happens when the front corner of a vehicle collides with a tree or utility pole at 40 miles per hour. In the real world, these sorts of accidents are more dangerous than others, in part because they bypass the front-end crush zones on most cars. TOP 5Most Researched Sedans 2013 Honda Accord MSRP : $21,680 2013 Hyundai Sonata MSRP : $20,895 2013 Nissan Altima MSRP : $21,760 2014 Honda Accord MSRP : $21,955 2013 Toyota Corolla MSRP : $16,230 Automakers have been rushing to make design changes to the front ends of their cars. Without a grade of acceptable or better, they cannot qualify for the IIHS' overall Top Safety Pick+ honor, given annually to the safest models on the market.

Next Chevy Silverado could get this built-in tailgate step

General Motors just received patent approval for a tailgate step in a pickup bed. And given the timing, don't be surprised if you see this on the upcoming 2019 Silverado pickup (not the mention its GMC Sierra twin), expected to arrive in late 2018. According to the patent, granted in December of last year, the whole mechanism is housed in the tailgate assemble. The magic happens when a portion of the top half of the tailgate swings down and a step folds out. There's also a handle that locks into position to help climb up into the bed. As trucks get bigger and taller over the years, it gets harder and harder to access the cargo bed. Ford's solution with the 2009 F-150 was a step that slides out from the end of the tailgate. Back then, Chevy made an ill-advised ad highlighting the feature for Ford. And while Howie Long mocked the F-150's "man step" Ford saw almost a third of its trucks with the option in the first year. The GM design seems to improve on Ford's idea as it appears to be wider and has a back to the lower step. That is, you don't have to worry about stepping through the ladder-rung design as on the F-150. Ford's tailgate step later spread to the F Super Duty, and other cargo access assists have proliferated through the truck world. On the most recent redesign, the Chevrolet Silverado took a trick from the Avalanche and added cutouts to the corners of the rear bumper that act as a foothold. Ford also offers a deployable side step, Chevrolet has running boards that scoot rearward with a kick of the boot, and Ram offers fixed wheel-to-wheel side rails. Nissan is in on the game too, with an optional folding step that tucks under the rear bumper. We don't expect Chevrolet to comment on when or if we'll see this feature in the showrooms. But given that engineers are already hard at work on the next Silverado and the timing of this patent lines right up with the new truck's development cycle, we'll be disappointed if this patent stays in the file cabinet. Related Video: