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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.

GM recalls 8,500 Chevrolet Malibu models for rear suspension glitch

According to a letter from General Motors to the National Highway Traffic Safety Administration, flaws in the build process of the 2013 Chevrolet Malibu have led to the recall of 8,519 cars. Units built between December 6, 2011 and January 15, 2013 may have been assembled with rear suspension cradles that had insufficient torque applied to certain bolts. That out-of-spec assembly could lead to issues ranging from slight noises to a loss of vehicle control.
The problem was first noticed in December of last year by a GM test fleet driver and eventually tracked back to the improperly torqued bolts on the suspension cradle assembled through July 2012 by a supplier located not too far from the Malibu's Detroit/Hamtramck Assembly Plant. Since an official NHTSA recall notice has not been issued yet, it isn't clear whether or not Detroit-built Malibus were the only ones affected (the 2013 Malibu is also built at GM's Fairfax Assembly Plant in Kansas City, Kansas). Dealers will fix the problem by inspecting vehicles for proper torque specs, retightening if not within specs and, in some cases, perform a rear-wheel alignment.

Chevrolet To Oversee Restoring Sinkhole Corvettes

What Mother Earth devoured, Chevrolet plans to resurrect. The carmaker said Thursday it will oversee restoration of the classic cars swallowed by a huge sinkhole beneath the National Corvette Museum in Kentucky. General Motors Design in Warren, Mich., will manage the painstaking work to repair the eight prize vehicles, the automaker said Thursday. The cars were consumed when the earth opened up early Wednesday beneath a display area when the museum in Bowling Green, Ky., was closed. No injuries were reported. The museum was open Thursday except for the area where the sinkhole occurred. Mark Reuss, GM's head of global product development, said the damaged vehicles rank as "some of the most significant in automotive history." "There can only be one 1-millionth Corvette ever built," he said, referring to one of the damaged cars. "We want to ensure as many of the damaged cars are restored as possible so fans from around the world can enjoy them." Just how the cars will be pulled out of the ground remains to be seen, said museum executive director Wendell Strode. The local fire department estimated the hole is about 40 feet across and 25 to 30 feet deep. The hole opened beneath part of the museum's domed section. "We feel pretty confident that most of the cars can be extracted," Strode said Thursday. "And we hope and believe that with just a little bit of luck, that all eight cars can be extracted and be part of the restoration." Chevrolet spokesman Monte Doran said some of the cars look to be in good shape, while others are buried in rubble. "It will likely be several weeks until we can get the cars out and assessed," he said. The GM Design team has helped restore other historic cars, but the Corvette project looks to be its biggest, he said. "These Corvettes are part of our history, and they want them restored properly," Strode said. "We're thrilled they're doing this." The cars looked like toys as they plunged into the hole, piled in a heap amid dirt and concrete fragments. The museum owns six of the cars while two - a 1993 ZR-1 Spyder and a 2009 ZR1 Blue Devil - are on loan from General Motors. The other cars damaged were a 1962 black Corvette, a 1984 PPG Pace Car, a 1992 White 1 Millionth Corvette, a 1993 Ruby Red 40th Anniversary Corvette, a 2001 Mallett Hammer Z06 Corvette and a 2009 white 1.5 Millionth Corvette. Pictures of the sinkhole showed a collapsed section of floor with multiple cars visible inside the hole.