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Recharge Wrap-up: Tesla details factory expansion; Ford and SunPower raise money for Sierra Club

Tesla has revealed the details of the upgrade of its Fremont, CA factory. One major change is the addition of a dedicated production space for the dual-motor P85D version of the Model S. Robots will be doing the battery installation on the Model S to save some time, and new export docks allow Tesla to get the cars out the door and on the way to their new owners more quickly. The new robots that move the cars around the factory have been named after X-Men characters, which makes our inner geeks smile. Check out the factory upgrade in the time-lapse video below and read more at Teslarati or at the Tesla Motors Blog. A program in Beijing for privileged registrations for EVs hasn't had much success. Of the 1,424 lottery winners, only about 30 percent went on to register an electric car despite a two-month extension of the deadline to do so. Buyers are likely discouraged by the lack of charging infrastructure, which the city hopes to ameliorate with the addition of 1,000 new charging stations by the end of the year, and by requiring new and renovated developments to set aside parking specifically for EV charging. Read more at Green Car Reports. The UC Davis Institute of Transportation Studies suggests that laws designed to protect dealers and consumers are stymieing the adoption of EVs. Laws like the ones certain states have in place that block or otherwise restrict Tesla's direct-to-consumer business model are not helpful for companies that want to introduce new products to the market. They prevent companies from passing on savings to customers for whom they would likely make the difference in a purchasing decision. One possible solution would be to allow exemptions to certain selling restrictions for a certain number of vehicles sold. "This could give automakers the degree of control needed to work out kinks with early customers, develop scalable processes for supporting PEVs, and ensure that effective dealer performance standards are in place before handing the reins over to wholly independent retailers," according to UC Davis ITS. Read more at the UC Davis website. Volkswagen says its environmental program, called "Think Blue. Factory," is meeting the automaker's own sustainability targets. The main purpose of the program is to move toward eco-friendlier carmaking at each of its plants worldwide.

Aluminum Ford F-150 earns five-star crash rating [w/video]

The scores are in, and the 2015 Ford F-150 has been awarded a five-star Overall Vehicle Score in the National Highway Traffic Safety Administration's testing. That makes it, according to Ford, the safest F-150 ever. "The five-star safety rating is a terrific example of One Ford collaboration and innovation," Vice President of Global Product Development Raj Nair said in a statement. "Our truck team worked together for years to deliver this accomplishment, using an unprecedented combination of advanced materials throughout the all-new F-150. The 2015 model is engineered to be the safest F-150 ever, which matters to customers who depend on this truck to not only get the job done, but also get them safely home." The new F-150's aluminum and high-strength-steel construction posed some unique challenges to truck's engineers. "The team had to invent new ways to manage crash energy, because advanced materials like high-strength steel behave differently," Matt Niesluchowski, the truck's safety manager. "We found that changing certain shapes led to a weight reduction, while also improving crash performance." Beyond the structural safety features, the 2015 F-150 is loaded with additional safety features, including an adaptive steering column and Ford's inflatable seat belts, that protects drivers in the event of a collision. Beyond that, there's the usual array of active safety features meant to prevent a crash in the first place, including Curve Control and forward collision warning with brake support. Check out Ford's full press release on its five-star score, as well as video on the truck's safety features.

2015 Ford Transit

As a segment, fullsize vans are stealth-fighter invisible on most consumers' radar. Visit a dealership for any of the four brands that offer them and you'll be lucky to find even one on display. These are commercial vehicles primarily, even more so than pickup trucks. Vans are the shuttles for plumbers, caterers, carpenters, concrete layers, masons, electricians, florists and flooring, and a huge part of this country's productivity is accomplished using them. At the moment, Ford is the 800-pound gorilla in that room - fully 41 percent of commercial vehicles wear a Blue Oval. So when Ford announced three years ago it would be ditching its commercial bread-and-butter E-Series, it meant the Transit that would be replacing the Econoline had huge, 53-year-old shoes to fill.
We were still a bit nostalgic about Econoline vans going away until going directly from the Transit first drive in Kansas City to an E-350 airport shuttle. Climb up through the Econoline's tiny double doors and bang your head on the opening, crouch all the way to your seat then enjoy a loud, rattle-prone, creaky, harsh ride on beam-hard seats while struggling to see out the low windows. This is an experience nearly every traveler has had. By comparison, the Transits we'd just spent two days with were every bit of the four decades better they needed to be. It cannot be understated just how much better the Transit is in every single way. The load floor is barely more than knee high. There's a huge side door, and hitting your head on a door opening is nearly impossible. Stand up all the way if you're under six-foot, six-inches - no more half-hunching down the aisle. There are windows actually designed to be looked out of. The ride is buttery smooth, no booming vibration from un-restrained metal panels and no squeaks. Conversations can be held at normal levels rather than yelling over the roar of an ancient V8. The seats are comfortable. The AC is cold. There are cupholders.
Enough anecdote-laying, what's in a Transit? We're talking about a very fullsized unibody van that's enjoyed a 49-year history in Ye Olde Europe. This latest iteration is part of the "One Ford" initiative, so it was designed as a global offering from the get-go, eschewing the body-on-frame construction the E-Series has used since 1975. Instead, the Transit integrates a rigid ladder frame into an overall frame construction made of high-strength cold-rolled and boron steel. The suspension is a simple but well-tuned Macpherson strut array up front with a rear solid axle and leaf springs.