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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.

Recharge Wrap-up: EV torque secrets, UC Davis maps future of biofuels

A UC Davis white paper maps out "Three Routes Forward for Biofuels," balancing investment risk with carbon benefits. The first option is "incremental," in which we tinker with the existing biofuel manufacturing infrastructure for small improvements over time. The "transitional" plan suggests integrating cellulosic production and other innovations with existing operations. The third route, called "leapfrogging," would mean building refineries based on new technology such as cellulosic and algae-based biofuels. The paper suggests ways the US could use these three routes together in different areas, and predicts the payoffs in terms of carbon emissions could be significant if the right people are willing to risk the capital. After all, financial advisers are always telling investors to diversify their portfolios to manage risk and rewards in the same way. Read more over at the UC Davis Institute of Transportation Studies. The Formula E Long Beach ePrix will offer free admission. The seventh round of the inaugural all-electric race season, which was moved from Los Angeles to the streets of Long Beach, will offer fans free grandstand and general admission. The race, which takes place on April 5, 2015, will use a 1.6-mile portion of IndyCar's Grand Prix of Long Beach. Read more at LA Times. Polaris is now offering its 2015 GEM electric vehicles, including the new street-legal eM1400 LSV. The passenger and utility vehicles come in two- to six-passenger configurations, many of which are street legal on roads with posted speed limits of up to 35 miles per hour. The eM1400 LSV utility vehicle seats two, offers 1,250 pounds of payload, 1,250 pounds of towing capacity, a top speed of 25 mph and a range of up to 45 miles. Its on-board charger plugs into any standard 110-volt outlet. Read more at Hybrid Cars and check out all the different configurations yourself at the Polaris website. In EVs, more torque does not always equal faster. Green Car Reports found this out when driving the Fiat 500e (with 147 pound-feet) against the similarly weighted Chevrolet Spark EV (with 400 pound-feet). The secret is, at least in part, in the gearing. The Fiat has a 9.6:1 reduction gear, making it quicker at lower speeds despite having far less available torque, while the Chevy uses a 3:1 ratio. The trade-off though, is in top speed. Furthermore, Chevy electronically limits the torque delivery at low speeds, as 400 pound-feet is a lot of launch for the little Spark EV to handle.

GM may kill 6 car models as it works with UAW to tackle sales slump

The president of the United Auto Workers union said on Thursday the union is talking with General Motors about the potential threat to plants and jobs from slumping U.S. car sales. GM's response will be more trucks and SUVs, and sources say at least six slow-selling car models may be killed off. "We are talking to (GM) right now about the products that they currently have" at underused car plants such as Hamtramck in Michigan and Lordstown in Ohio, and whether they might be replaced with newer, more popular vehicles such as crossovers, Dennis Williams told reporters. "We are tracking it (and) we are addressing it," Williams added. GM has cut shifts at several U.S. plants this year as inventories of unsold cars have ballooned. Industry analysts said more jobs could be at risk as the automaker wrestles with permanently shrinking production of small and midsized sedans. GM is reviewing whether to cancel at least six passenger cars in the U.S. market after 2020, including the Chevrolet Volt hybrid, which could be replaced in 2022 with a new gasoline-electric crossover model, Reuters has learned from people familiar with the plans. Other GM cars at risk include the Buick LaCrosse, Cadillac CT6, Cadillac XTS, Chevrolet Impala and Chevrolet Sonic, sources said. Some analysts have singled out GM's Hamtramck plant in Detroit as one of the most vulnerable because of plummeting car sales. The plant, which opened in 1985, builds four slow-selling models: Buick LaCrosse, Chevrolet Impala, Cadillac CT6 and Chevrolet Volt. In the first half, it built fewer than 35,000 cars, down 32 percent from the same period in 2016, according to suppliers familiar with GM's U.S. production schedule. The typical GM assembly plant builds 200,000-300,000 vehicles a year.COMING ATTRACTIONS: TRUCKS AND SUVS GM must "create some innovative new products" to replace slow-selling sedans "or start closing plants," said Sam Fiorani, vice president of AutoForecast Solutions. The auto maker already has begun to shift future production plans from cars to trucks, according to Morgan Stanley auto analyst John Murphy. He estimates that fewer than 10 percent of the new vehicle models that GM will introduce over the next four years will be passenger cars, with the rest divided among trucks, SUVs and crossovers. GM plans to add production of the new Cadillac XT4 crossover next year to its Malibu sedan plant in Fairfax, Kansas.