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EcoCar2 is on the hunt for a better, cleaner Chevy Malibu [w/video]

The students spent three years transforming an ordinary Chevy Malibu into a revolutionary vehicle. Not far from the building where General Motors once invented the Chevy Volt, a dozen or so college students are standing on the blacktop alongside a test track, watching a professional driver push the limits of a plug-in hybrid car they've built that's far more radical. These students, from Colorado State University, have spent the past three years transforming an ordinary Chevy Malibu into a revolutionary vehicle. At first glance, it still looks like a regular sedan. But under the hood, they've installed a hybrid powertrain that contains both hydrogen and electric power sources. Even by the standards of the Department of Energy competition they're participating in, it's an outlier. That's exactly what they had in mind. "We didn't want to come here and tell them how to build a better Volt," said Tom Bradley, faculty adviser for the Colorado State team. "They already know how to do that. We can tell them how to think about these possibilities in a whole new way." After three years of work, it all comes down to this. The Colorado State team was one of 15 that came to GM's Milford Proving Grounds last week for the final stretch of the EcoCar2 competition, which challenges regular college students who have no automotive experience to do nothing less than reinvent the American car. The teams have come from across North America, and include schools like Ohio State and Virginia Tech that have a long history of participating in similar competitions, and schools like the University of Washington and Embry-Riddle Aeronautical University that are here for the first time. After three years of work, it all comes down to this. The teams have operated 24 hours a day for almost two weeks here at the Proving Grounds, running a gamut of tests that include a 310-point safety inspection, emissions and energy-consumption tests and road tests, in which professional GM drivers ensure they're road worthy. The winning team will be announced tonight in Washington D.C. Revolutionary cars, ordinary package While other green-car competitions encourage extreme designs, this one comes with a somewhat constraining twist: Yes, students must improve fuel economy and reduce emissions, but in the end, they still have to have a car that would appeal to mainstream customers. In practical terms, that means they must keep conveniences like air conditioning and trunk space.

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.

Before Chevrolet's Redline, there was the Saturn Red Line

While Chevy rolls out Redline special editions across more of the lineup at this year's Chicago Auto Show, we've been eating some 'member berries and started thinking about the last time GM used the term. Back in 2004, Saturn rolled out Red Line (two words) editions of the Ion and Vue. The lineup was joined by the Sky Red Line in 2007, and the second-generation Vue kept the tradition going in 2008. This was in the heady days of the mid-2000s, before the financial crisis and GM's bankruptcy reorganization that saw the end of Saturn. The press release headline for the 2008 Sky is now cringe-worthy: "Hot-selling Sky helps drive Saturn product renaissance." Performance lineups were the hot new thing, as automakers attempted to cash in on the tuner trend popularized by The Fast and the Furious. Chevy had SS models, Pontiac had GXP, and Saturn had Red Line. Across the Detroit Metro area, Dodge had a slew of SRT models, and Ford's Special Vehicle Team brought us the SVT Lightning pickup, the SVT Focus, and a smattering of hopped-up Mustangs. The performance cred of Red Line models varied from car to car. The Ion Red Line shared the same engine as the original Chevy Cobalt SS, a 205-horsepower supercharged 2.0-liter four-cylinder, 65 hp more than stock. Car and Driver tested one with a 0-to-60-mph time of 6.1 seconds and said the Ion "tears down the wall that has separated enthusiasts from the Saturn brand for so long." The Vue Red Line, meanwhile, came with the same optional Honda-sourced 3.5-liter V6 you could get in the regular Vue, and added a stiffer, lower suspension, bigger wheels with more aggressive rubber, and recalibrated steering assist. When the Vue was redesigned for the 2008 model year, the Vue Red Line was a similar proposition. The engine was now from GM, and up 7 horsepower to 257, but you could get it in both Red Line and XE trim. Aside from the tire and suspension upgrades, Red Line models now came with a unique front fascia and rear exhaust cutouts. The most exciting Red Line, of course, was the high-performance version of the Sky roadster, which shared underpinnings with its Pontiac Solstice twin. This model came with GM's hot 2.0-liter Ecotec Turbo, good for 260 horsepower. The extra power was crucial in covering up the Sky's unfortunate manual gearbox ratios, which left the non-turbo model aching for torque in lower gears. As we all know, Saturn was taken by the grim reaper in 2009 after an attempt to sell the brand to the Penske Group.