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Recharge Wrap-up: Tesla details factory expansion; Ford and SunPower raise money for Sierra Club

Tesla has revealed the details of the upgrade of its Fremont, CA factory. One major change is the addition of a dedicated production space for the dual-motor P85D version of the Model S. Robots will be doing the battery installation on the Model S to save some time, and new export docks allow Tesla to get the cars out the door and on the way to their new owners more quickly. The new robots that move the cars around the factory have been named after X-Men characters, which makes our inner geeks smile. Check out the factory upgrade in the time-lapse video below and read more at Teslarati or at the Tesla Motors Blog. A program in Beijing for privileged registrations for EVs hasn't had much success. Of the 1,424 lottery winners, only about 30 percent went on to register an electric car despite a two-month extension of the deadline to do so. Buyers are likely discouraged by the lack of charging infrastructure, which the city hopes to ameliorate with the addition of 1,000 new charging stations by the end of the year, and by requiring new and renovated developments to set aside parking specifically for EV charging. Read more at Green Car Reports. The UC Davis Institute of Transportation Studies suggests that laws designed to protect dealers and consumers are stymieing the adoption of EVs. Laws like the ones certain states have in place that block or otherwise restrict Tesla's direct-to-consumer business model are not helpful for companies that want to introduce new products to the market. They prevent companies from passing on savings to customers for whom they would likely make the difference in a purchasing decision. One possible solution would be to allow exemptions to certain selling restrictions for a certain number of vehicles sold. "This could give automakers the degree of control needed to work out kinks with early customers, develop scalable processes for supporting PEVs, and ensure that effective dealer performance standards are in place before handing the reins over to wholly independent retailers," according to UC Davis ITS. Read more at the UC Davis website. Volkswagen says its environmental program, called "Think Blue. Factory," is meeting the automaker's own sustainability targets. The main purpose of the program is to move toward eco-friendlier carmaking at each of its plants worldwide.

Aluminum lightweighting does, in fact, save fuel

When the best-selling US truck sheds the equivalent weight of three football fullbacks by shifting to aluminum, folks start paying attention. Oak Ridge National Laboratory took a closer look at whether the reduced fuel consumption from a lighter aluminum body makes up for the fact that producing aluminum is far more energy intensive than steel. And the results of the study are pretty encouraging. In a nutshell, the energy needed to produce a vehicle's raw materials accounts for about 10 percent of a typical vehicle's carbon footprint during its total lifecycle, and that number is up from six percent because of advancements in fuel economy (fuel use is down to about 68 percent of total emissions from about 75 percent). Still, even with that higher material-extraction share, the fuel-efficiency gains from aluminum compared to steel will offset the additional vehicle-extraction energy in just 12,000 miles of driving, according to the study. That means that, from an environmental standpoint, aluminum vehicles are playing with the house's money after just one year on the road. Aluminum-sheet construction got topical real quickly earlier this year when Ford said the 2015 F-150 pickup truck would go to a 93-percent aluminum body construction. In addition to aluminum being less corrosive than steel, that change caused the F-150 to shed 700 pounds from its curb weight. And it looks like the Explorer and Expedition SUVs may go on an aluminum diet next. Take a look at SAE International's synopsis of the Oak Ridge Lab's study below. Life Cycle Energy and Environmental Assessment of Aluminum-Intensive Vehicle Design Advanced lightweight materials are increasingly being incorporated into new vehicle designs by automakers to enhance performance and assist in complying with increasing requirements of corporate average fuel economy standards. To assess the primary energy and carbon dioxide equivalent (CO2e) implications of vehicle designs utilizing these materials, this study examines the potential life cycle impacts of two lightweight material alternative vehicle designs, i.e., steel and aluminum of a typical passenger vehicle operated today in North America. LCA for three common alternative lightweight vehicle designs are evaluated: current production ("Baseline"), an advanced high strength steel and aluminum design ("LWSV"), and an aluminum-intensive design (AIV).

2015 Hennessey VelociRaptor 600 fills an F-150 Raptor-sized void

Ford is rumored to possibly debut a new F-150 Raptor at the upcoming Detroit Auto Show in January, but whether that's the case or not, Hennessey Performance is ready to fill the muscle truck niche now with its latest VelociRaptor 600 Supercharged based on the 2015 F-150. The fantastically named VelociRaptor package has been available on the regular Raptor for the past few years, taking power up to 600 horsepower or more, depending on what the buyer desired. With the latest one, the performance truck is now based on the aluminum-bodied F-150, specifically the FX4 Super Crew model with the 5.0-liter V8. "Having Ford's world-class new truck design, with a weight savings of nearly 700 pounds, our VelociRaptor 600 Supercharged will have an even greater level of performance and driving excitement," said founder John Hennessey in the company's release. The heart of VelociRaptor is the Roots-type supercharger running at 8 psi on the V8. With help from upgraded fuel injectors, a proprietary engine management system and stainless steel exhaust, it boosts grunt from a stock 385 horsepower to over 600 hp. To make sure that power gets to the road, the package also includes 33-inch BFGoodrich mounted on 17-inch Hennessey wheels. For buyers in need of more, the company offers optional parts including an off-road coilover suspension, different front and rear bumpers, a winch, LED light bar and Brembo brakes. Speaking to Autoblog, Hennessey said he feels confident that the latest VelociRaptor could do high-four-second sprints to 60 miles per hour, compared to the outgoing model in the low-five-second range. Prices for the VelociRaptor start at $73,500, which includes the donor F-150, and orders are open now. Actual deliveries should start by March at the latest, according to Hennessey. The company also plans to offer a similar package for EcoBoost F-150s later. Scroll down to read the full announcement about this muscle truck. Introducing the 2015 Hennessey VelociRaptor 600 Supercharged Texas tuner adds power and improved off-road capabilities to Ford's all-new aluminum bodied pick-up trucks December 16, 2014-For immediate release Sealy, Texas-For the past five years, Ford F-150 truck enthusiasts have had the special opportunity to own the SVT Raptor. With 411 hp and baja pre-runner capabilities, the Ford Raptor was one of the most capable 4x4's ever built. Sadly, Ford Raptor production has ended, leaving a void in the market for 2015.