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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: BYD unveils 60-ft electric bus, Honda sticking with hybrids in Europe

BYD has debuted a 60-foot electric bus at the American Public Transportation Association Expo in Houston, TX. The Lancaster bus, as it is called, has a 120-passenger capacity and can drive over 170 miles on a single charge. The articulated bus features low floors and no steps, thanks to in-wheel hub motors. BYD also displayed a 40-foot electric bus that drove the 1,500 miles to the show under its own power (recharging along the way, of course). Read more in the press release below. Honda says it will continue to sell hybrids in Europe, despite the fact that it has stopped selling the CR-Z and Insight due to slow sales. "Our focus at the moment is on our 1.6-liter diesel but we haven't forgotten about hybrid technology," says Honda Europe's Philip Ross. Honda will sell the next-generation Fit (badged as the Jazz) in Europe when it launches next summer, and will sell the next-gen hybrid version beginning in 2016. Honda sold 4,500 of the Jazz hybrid in Europe last year. Read more at Automotive News. XL Hybrids is selling its XL3 Hybrid Electric Drive System in California. The news comes after the California Air Resources Board issued an executive order allowing the aftermarket hybrid conversion for 2012-2014 Chevrolet Express and GMC Savana vans. The XL3 Hybrid regenerative braking conversion increases real-world mpg by about 25 percent. Read more in the press release below. NRG eVgo has finished installing 60 charging stations at the Sony Pictures Entertainment studio lot and offices in Culver City, California. The Level 2 chargers, which will be managed by NRG eVgo, allow employees to charge their EVs during the workday. An average of 90 EVs and PHEVs park at the studio headquarters every day, thanks in part to Sony Pictures' Alternative Vehicles Incentive program for its employees. Learn more in the press release below. Pennsylvania's Public Utility Commission will allow operators of EV charging stations to set prices based on kilowatt hour usage. This change ensures that drivers pay for the actual energy they use, rather than the time they spend charging, since different cars can charge at different speeds. Car Charging Group has already begun using the per-kWh fee structure at its charging stations throughout the state. Other states that allow kWh pricing are California, Colorado, Florida, Hawaii, Illinois, Maryland, Minnesota, New York, Oregon, Virginia and Washington. Read more in the press release below.

GM executive chief EV engineer says reducing cost of plug-in vehicles is 'huge priority'

As we know, another major automaker investing heavily in electrified vehicles is General Motors, and it's doing things much differently than rivals BMW, Ford or Nissan. The Chevrolet Volt extended-range EV is a modest seller at its $35,000 sticker price but a huge hit with owners. The Chevy Spark BEV, still in limited availability, puts smiley faces on its owners and drivers. The just-introduced Cadillac ELR, a sharp-looking, fun-driving $76,000 luxocoupe take on the Volt's EREV mechanicals, has admittedly low sales expectations. With this interesting trio in showrooms and much more in the works, the third vehicle electrification leader I collared for an interview at Detroit's North American International Auto Show (see #1 and #2) was Pam Fletcher, GM's executive chief engineer, Electrified Vehicles. ABG: Why do your EREVs need four-cylinder power to extend their range when BMW's i3 makes do with an optional 650 cc two-banger? "We designed [the Volt and the ELR] to go anywhere, any time" - Pam Fletcher PF: I get that question all the time: why not something smaller? You don't really need that much. You use the electric to its ability, then you just need to limp. But we designed those cars to go anywhere, any time, and we don't want their performance to be compromised. If you're driving through the mountains, we don't want you to be crawling up grades, or to be limited on any terrain. So it's optimized to be able to travel literally the biggest grades and mountain roads around the globe at posted speeds. Because what if you can't? Another good reason: when the engine is on, you have to run it wide open throttle, max speed, most of the time. And while we can do a lot with acoustics, and the ELR has active noise cancelation, a small-displacement, low cylinder-count engine at high speed, high load all the time isn't something you want to live with. That's how we came up with the balance we did among the key factors of performance, NVH [noise, vibration and harshness] and range. ABG: Where you go from here? Is the range-extender engine due for an update? PF: We know and love the current Volt, and there is still a lot of acclaim about it, so we think it's a good recipe. But we are heavily in the midst of engineering the next-generation car, which I think everyone will love and be excited about.