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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.

2020 Chevrolet Tahoe, Suburban and GMC Yukon all spied with production lights

One of our spy photographers just caught a smattering of full-size GM SUVs out testing, including the Chevrolet Tahoe, Suburban and GMC Yukon. Previous spy photos of the next-generation of these big GM SUVs have revealed that GM is going with an independent rear suspension design, and these shots confirm the news once again with our best look at the hardware yet. Check them out from the rear, lined up like ducks in a row to see the beefy control arms down there. This will undoubtedly give the big SUVs a more compliant ride, and should bring it back into touch with the refinement from the Ford Expedition and Lincoln Navigator. The new bits we get to see with these shots are production headlights and taillights that are shaping up to look pretty neat. Most distinguishable are the GMC Yukon's LED DRLs. These look a lot like the C-shaped LEDs outlining the headlights on the Sierra, but they have an extra LED strip on top of the C. The parts of the taillights that we can see look significantly different than that found on the Sierra, showing GM is planning on having a great deal of differentiation there. We can sort of see through the mesh covering the grille to what appears to be a classic horizontal bar style front opening. Chevy is predictably dialing the crazy LED strip design back for the Tahoe and Suburban. The parts that are lit up look a whole lot like the headlight fixtures on the 2019 Silverado. That truck uses a stack of lights with the actual headlights separated from the DRLs. We can see the same thing going on here, with the headlight up top and curved LED DRL strip sitting below. It's tough to say if the designs are exactly alike, but we expect to see an extremely Silverado-esque look once all the camouflage comes off. Chevrolet's taillight design differs from its donor truck like the GMC, showing off a curved, vertical series of LEDs out back. Once production lights start popping up like this, we know the vehicle is moving closer to its end game. A reveal sometime later this year could be in the cards for GM's next batch of full-size SUVs. It certainly needs them quick, as Ford rockets ahead with increased Expedition production announced earlier this week.

How GM engineers are using diaper 'snow' to keep you warm

Testing how snow affects General Motors' vehicles isn't really a problem right now for the company's engineers, but in the dog days of summer the process isn't exactly easy. The only real option is for them to book time at the automaker's climatic wind tunnel. However, a flash of brilliance from an engineer allows snow to be simulated regardless of the temperature outside, and the discovery is all because of his daughter's wet diaper. The realization came to GM Thermal Systems engineer Nicholas Jahn while he was swimming with his daughter and noticed how her diaper ballooned in size in the water. He found out the substance that makes this possible is called sodium polyacrylate. When the material gets wet it grows and forms fluffy flakes that are a close imitation of snow. Best of all, the stuff can be prepared easily any time of the year, and it's reusable. The engineering team uses the material to test the effectiveness of the heating systems of GM's vehicles. They spread the sodium polyacrylate over the inlets at the base of the windshield to obstruct the airflow and then crank the heater. After some time, they can see how much is being sucked into the system and design more efficient systems in the future. See how the process works in the video above and read about the diaper discovery in GM's press release below. Diapers Change Chevy Cruze Winter Warm-up Time GM validation engineer uses diaper material "snow" to reduce frigid drives 2015-01-06 DETROIT – An item commonly found on an infant's changing table is helping General Motors' engineers simulate snow year round, ensuring heating systems in cars like the 2015 Chevrolet Cruze can quickly and efficiently warm its interior. Packed snow can prevent air from entering the inlet panel at the bottom of the windshield, obstructing the flow of air into the heating system and reducing the amount of air it can push out. This can lead to less efficient warming of the car's interior and windshield defrosting. "The last thing anyone wants to do when it's freezing cold out is scrape their windshield," said Nicholas Jahn, GM Vehicle Thermal Systems engineer. "The testing we perform on the Chevrolet Cruze with the diaper material allows us to maximize the car's heating capabilities." Ironically, Jahn stumbled upon his diaper-based testing method in the middle of summer. During a swim with his daughter, he noticed her diaper multiplied in size when it came into contact with water.