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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.

Audi S4 drivers are the most accident-prone, insurance report says

Culling data from more than 4.6 million automobile insurance applications, researchers at the Insurify insurance comparison marketplace picked a winner — or more to the point, a loser — in its determination of the car model with the most accidents so far in 2023: the Audi S4. Why does the sporty, luxury-class German sedan rank so high (or so low)? The organization found that S4 drivers, piloting a car with almost 350 horsepower, are among those who collect the most speeding tickets, and that they get into accidents at a rate 54 percent higher than the national average. If the S4 isnÂ’t a surprise with an at-fault accident rate of 11.7 percent, consider the “family friendly” brand that appears three times on the Insurity list: Subaru. It is represented by three models, including the turbocharged WRX and XV Crosstrek, and at the better-performing bottom of the list, the Subaru Impreza, with an accident rate of 10.3 percent.  In 2023, 7.6 percent of U.S. drivers were involved in at least one at-fault accident in the prior seven years. For drivers of cars on this list, the average at-fault accident rate was 10.5 percent, meaning these drivers are 1.4 times as likely to have an at-fault accident on record. According to its statement, the Insurity data science team explored key safety features, driver behavior, and Insurance Institute for Highway Safety (IIHS) evaluations to pinpoint possible reasons behind these carsÂ’ high accident rates. Following is the list, counting down to the models with most reported accidents: 10. Subaru Impreza (percentage of drivers with a prior at-fault accident on record: 10.3 percent; MSRP base model): $19,795) 9. Kia Niro (percentage of drivers with a prior at-fault accident on record: 10.4 percent; MSRP base model): $26,590) 8. Chevrolet Silverado LD (percentage of drivers with a prior at-fault accident on record: 10.4%, MSRP base model): $34,500) 7. Subaru XV Crosstrek (percentage of drivers with a prior at-fault accident on record: 10.5 percent, MSRP 6. Subaru WRX.(percentage of drivers with a prior at-fault accident on record: 10.7% MSRP base model): $29,605) 5. Toyota GR86 (percentage of drivers with a prior at-fault accident on record: 10.8 percent MSRP base model): $29,900) 4. Hyundai Veloster N (percentage of drivers with a prior at-fault accident on record: 10.9 percent; MSRP base model): $32,500) 3.

Recharge Wrap-up: Range-extended EV taxis in London, 2016 Chevy Volt interior two years old

The first Metrocab range-extended EV taxis are operating on the streets of London. The cabs use a 12.2-kWh battery and two 50-kW motors, as well as a 1.0-liter gasoline range extender. Fuel economy is 98 MPGe on the ECE101 cycle, and total driving range is over 348 miles before needing to charge or refuel. Cabbies can expect to save GBP20 to GBP40 (about $30 to $60) per day on average. "The cash savings on fuel are significant, the ride and comfort outstanding, and my first customers are thrilled with the new cab," says the first operator of the new EV taxi, Preston Morris. "With its air suspension providing unrivaled comfort, panoramic glass roof for views of the city and silent powertrain, what's not to like?" Read more in the press release below. Chevrolet has had the interior design of the 2016 Volt finished for two years already, according to GM interior designer John McDougall. Beginning around 2010, GM received sketches from designers worldwide before narrowing it down to a handful of designs. Then the top three choices were molded from clay. The chosen theme was then refined for up to 18 months. "Every little thing you can imagine goes into that," says McDougall. "The glare angle from the windows, the placement of the controls, the placement of the seat. You have to create something that's beautiful and functional." Read more at GM Authority and at Inside EVs. More details have emerged about the Second Life Batteries Alliance. Vattenfall has announced a research project in partnership with BMW and Bosch to use retired EV batteries for stationary, grid-connected energy storage in Hamburg, Germany. Over 100 lithium-ion batteries from BMW i3 and ActiveE vehicles will make up a two-mWh storage unit for grid balancing, enough to power 30 four-person households for a week. The system is "compact enough to fit in a small building," says Bosch. Such storage systems are especially fit for storing and moving alternative forms of energy, which often fluctuate in supply more than electricity from a traditional power plant. Vattenhall will operate the storage unit for 10 years, with Bosch managing the batteries, during which time the three partners hope to learn more about battery applications and their performance over time. Read more at Green Car Congress, or in the press release below.