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Tesla Model S and Tesla Lawyer BS

Oh wow, Tesla’s PR tailspin keeps getting worse. If you hadn’t heard, the startup car company filed suit last week in the UK against the BBC TV show Top Gear for pretending that the car broke when it didn’t. Yes, Top Gear’s actions are reprehensible. Sadly this isn’t the first I’ve heard of Clarkson et al writing scripts beforehand, sticking to them even when reality doesn’t measure up. No, that’s not fair to the car companies or the viewers. But to file suit? C’mon, Tesla! You’re supposed to be a young, energetic Silicon-Valley startup: you should be thinking outside the box not banging your heads against the inside of one. Instead of calling lawyers, you should have called some actors… and made your own Top Gear-esque spoof taking the piss out of Clarkson and company. It’s sad enough that so many people already distrust Tesla – but nobody likes a snitch.
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Shame, that, since that little Tesla Roadster remains a really, really cool car. Ah cars: that brings us to the point of this Blog. Let’s talk about the Model S sedan that the collective automotive world has been waiting for. In a renewed effort to achieve transparency with the media, Tesla invited a bunch of journalists to their Palo Alto, California headquarters a few weeks ago – and showed us where the Model S stands.

First and foremost, Roadster drivers have now accrued more than 10 million miles in their cars, giving Tesla a huge well of real-world EV data from which to learn – and the company is wisely making use of that information. Whereas the Roadster was based on an existing, conventionally powered car (the Lotus Elise), the Model S sedan is a ground-up, in-house design, allowing Tesla to optimize their sedan in ways never possible with the Roadster.

To that end, the Model S battery pack forms an integral part of the vehicle structure. Rather than having a case just to carry the approximately 7000 battery cells, the outside of the pack also acts as a structural member. Attaching the PEM (or Power Electronics Module) directly to the motor and gearbox improves efficiency by minimizing the length of electrical connections.

Tesla promises that the Model S battery pack will be “the world standard and well set a new benchmark in energy density” and we don’t doubt it, but the company won’t disclose the pack’s weight or capacity. Peak output will be somewhere around 300kW, which translates to roughly 400 hp, and they say the biggest battery will give the Model S a range of 300 miles.

Smaller capacity batteries will be available later, as we’ve heard, but they will retain the same external dimensions (a requirement because of the structural outer shell of the battery.) They will also use different chemistry for less range, which will likely keep them less expensive though likely not much lighter.

With the pack located beneath the vehicle floor, Tesla has designed for very quick battery pack swaps (in about a minute) provided the infrastructure for pack-swapping becomes available.

During our visit, we saw workers working on several of the twenty so-called “Alpha” cars that have already been built. The fleet of Alpha cars will be driven over the equivalent of 250,000 miles in a few months for durability testing . Crash-testing is currently in progress, and engineers are working directly with the managers who will be working at the Freemont, CA plant where the Model S will be built to optimize the car for ease of assembly and quality. “Quality is designed in from the outset. It’s not dependent on whether the line workers have the right screwdriver,” says an engineer who previously worked with a large-volume English carmaker not known for, um, reliability.

The Alpha cars were built by hand in Michigan. This summer, the first Beta cars will start to come together, assembled by the suppliers that will eventually transfer their equipment to the Freemont plant. Beta cars will be built in batches and will be used for fine-tuning. And then the Tesla Model S is scheduled to go into real series production.
The BMW 5-series Gran Turismo is a thorn in the side of fans of the German brand’s 5-series wagon. The sedan meets wagon meets SUV has left long-time BMW enthusiasts scratching their heads due to the Gran Turismo’s weight, less-than-sporty styling, and subpar (for the brand) driving dynamics. As is common with this type of vehicle, it tries to be everything and as a result, it shines in very few areas. The Gran Turismo (GT) was offered alongside the last generation 5-series wagon (E61) and sedan (E60) during the 2010 model year. For 2011, Americans had only the choice of either the new 5-series sedan (F10) or 5-series GT (F07). A new 5-series wagon (F11) is available but not in the States. BMW USA product planners don’t see room in the market for both the GT and the wagon. I recently spent 10-days in England in a 530d SE version of the wagon to see if we are missing something in the USA.
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The newest 5-series sedan and wagon both moved away from the Chris Bangle design of the previous version and picked up a style that’s a mix of the soon to be replaced 3-series (E90/E91/E92) and latest 7-series (F01/F02). The interior is heavily influenced by the 7-series as well. Compared to the old 5-series wagon, the new car picks up a bit more space inside and the rear seats are able to fold in 3-sections (40/20/40 split) by either buttons on the top of the rear seats or with release levers inside the cargo area. An interesting feature that BMW recently previewed but wasn’t on our test car is the ability to open the tailgate by moving your foot under the rear bumper (as long as you have the key in your possession). It’s a nice trick to use when your arms are full of grocery bags or children. Despite the bump in size, the BMW wagon still gives up some cargo space compared to its Mercedes E-Class competition. The Mercedes is also the only car in the class to offer two additional rear-facing jump seats.

The Mercedes may still offer more space and people carrying ability but the BMW has always been more about driving dynamics than outright interior volume. The new 5-series sedan has taken some heat in the international press due to its driving dynamics. The wagon doesn’t change this complaint. The only mechanical difference between the wagon and the sedan is that the rear springs are auto levelling air compared to conventional springs in the sedan (this was also the case with the E61). When you’re really honking on the BMW on the back roads, the 5 wagon can still dance and make ground quickly but not with the same level of driver’s involvement as previous versions of the 5-series. The car feels softer and heavier and the new electric power steering just doesn’t offer the same feedback and tactility of BMW’s hydraulic systems. It’s interesting that BMW also fits electric power steering to the four-cylinder-powered 3-series models in Europe. I tested a 320d M Sport wagon in England in 2010 and I found the steering miles better compared to this 530d wagon. Volkswagen and Ford also build impressive electric steering systems so you can’t just blame it for not being hydraulic. I think BMW can make the new 5-series drive far better without a major rehash of the mechanicals of the car. It may just be a matter of tweaking and development. Behind the wheel, you can fiddle with the various chassis settings but the car just never feels right.

Speaking of settings, I’ve been surprised how many reviews of the new 5-series have failed to clarify what options are fitted to the test car. The 5-series (sedan and wagon) offers a multitude of different suspension, steering, and wheel options that make a huge difference on how the car drives. As an optional extra, you can fit active steering (which includes rear-wheel steering and is only offered on rear-drive 5-series), adjustable dampers, and active sway bars. Our 530d had the active dampers and sway bars but did not have active steering. Wheels and tires are another can of worms in the voodoo world of ride and handling balance. The 530d comes standard with 17-inch wheels and run-flat tires. Our car was fitted with the plus-two setup, 19-inch wheels with Goodyear Excellence performance run-flat tires (245/40-YR19). The large wheels and low profile run-flat tires cause the BMW to ride especially rough over broken pavement. The ride isn’t necessarily poor but there is a large amount of shutter and crashing through the cabin when running over less-than stellar pavement. Without testing other setups back to back, I’d say the 18-inch option is the way to go for the best aesthetics to ride quality balance. I found the combination of the low profile tires with the suspension in sport mode to be especially harsh but nice for ultimate grip and control in the corners. Sport mode also adds a nice dose of additional body control at the expense of rebound dampening that is too aggressive. Still, most UK road tests reveal that active dampers are a must-have option for the best ride quality. To make things more complicated, BMW also offers a non-adjustable sport suspension on M Sport model wagons and sedans but the suspension setup goes back to SE specification (like our test car) if you spec the optional adjustable dampers. The available active steering is another grey area. I have not personally tried it but I’ve never been a fan of the system in other BMW models. Reviews of active steering in the 5-series by the UK press have been mixed. So, it’s quite clear that the multiple combinations of options on the 5-series make it a “must try before you buy” vehicle. I recommend having a go in multiple configurations before pulling the trigger.
What started as a clever way to play up the latest Marvel superhero picture — Thor, for those of you who’ve never stepped foot in The Android’s Dungeon — wound up triggering a bomb scare in downtown Ann Arbor, Michigan — right in front of our office — earlier this afternoon. So, how’d this excitement come to pass? Earlier this week, we received a large, ungainly package from Acura’s ad agency, which contained a large black box billed as an agent test kit for the “Strategic Homeland Intervention, Enforcement, and Logistics Division“ (spoiler alert: S.H.I.E.L.D is the government agency charged with investigating Thor’s arrival on earth).
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Inside, a number of “tests” — including one that required the user to reanimate a (fake) scorpion with a sugar cube — were designed to be clever — if not somewhat nerdy — ways to incite a laugh, and inscribe Thor into our memory banks. We found the execution odd, what with the fake toggle switches, vial of blue fluid, and one test that referenced detonation, but chuckled, and sent it into our recycle bin. It, along with other recyclables, were collected and placed at the corner of Fourth and William, where they sat for two days before our collection company picked them up.

We’d forgotten about the box until this afternoon, when we noticed growing commotion from down below.

Police began diverting traffic away from Fourth Avenue shortly after 1:00 pm, and directed pedestrians away from the area (interestingly, our building was never evacuated nor notified of the going-ons below).

Early reports suggested a suspicious package had been found at the post office across the street, but as details continued to make their way upstairs, we’d heard said package was actually found on the west side of Fourth Avenue. In the mean time, the FBI, ATF, U.S. Marshals, and the Michigan State Police made their way beneath our windowsills.

That sparked a memory, prompting us to run again to our windows. Most of the recyclables were gone, but for some reason, the Thor box, with Acura and Thor logos (and “In Theatres May 6″) plainly visible for the world to see, was still sitting at the curb. Was this novelty causing all the excitement?

Yep. Turns out a passerby spotted the box, its unusual switchgear and the word “detonation,” and pointed it out to a police officer. Thanks to a bomb threat that had apparently been phoned into the bus station down the street, all hands were promptly called to deck.

Associate editor Eric Tingwall placed a call into the AAPD, and promptly identified the package as being nothing more dangerous than press materials and cheesy jokes. Bomb squad technicians — dressed to the nines in Kevlar — quickly moved in, scanned the box, and issued the all-clear shortly after 2:15 p.m.

All’s well that ends well, but one thing’s for certain: we’ll be keeping a little closer eye on our recycling service’s pick up performance from now on.
In his latest self-aggrandizing book, Car Guys vs. Bean Counters, Maximum Bob Lutz talks about running into the inept, choleric Chairman of General Motors, Roger Smith, in a hotel lobby in Europe. Lutz characterizes Smith as “The man who locked GM into ‘all front-wheel-drive.” Talking about the then-forthcoming rear-wheel-drive Ford Sierra, Smith fumed that “The whole world is going to front-wheel drive. Everybody! The whole industry! You’ll be all alone, and the Sierra will be a flop!” Lutz goes on to say, “Well, the whole world didn’t, and the Sierra wasn’t…”
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Unfortunately, Smith’s illogic about “all front-wheel drive” has found another unhappy home — at Ford. I don’t know who the Smith surrogate might be. Derrick Kuzak, Ford’s Global Product Development chief? Alan Mulally himself? Someone must be responsible for the fact that there is no replacement plan for the Lincoln Town Car, and all Lincoln cars will henceforth be front-wheel-drive. This is, of course, a very bad idea. A decade or so back, there was an air-suspended puffed-up Taurus sold as the Lincoln Continental four-door. Didn’t last in the market, didn’t sell very well.

Our sister magazine, Motor Trend, notes in the August issue that “Ford brass knows Lincoln needs distinct product and a modern rear-drive platform…” but doesn’t think it can afford one. The solution is at hand, very inexpensively, but no one at Ford seems imaginative enough to do a bit of in-house hot-rodding to turn the fully-amortized, very satisfactory but obviously very ancient (1979) Panther platform into a profit center. Panther is the platform underlying the (highly profitable) Crown Victoria and Lincoln Town Car. If you haven’t examined one of these things recently — there has been no PR work, no road tests, no technical articles concerning Panther for years — you may not be aware that the front crossmember is a massive alloy casting visually entirely worthy of an Aston Martin, complete with a front-steer rack and pinion steering box. It is very solidly reliable in taxi, limo and cop car service, and has been from around 2003. The chassis frame is dirt simple, with parallel side rails that can be — and were — made in different lengths at essentially no cost. Yes, it’s a hunk of ironwork, but it’s cheap, cheap, cheap. And strong. And adaptable. And long-since paid for.

True, there’s no independent rear suspension. But there must be four or five fully-tooled IRS systems in the Ford warehouses. Mustang Cobra, Ford Explorer, Lincoln trucks, who knows what could be cobbled together quite easily from existing components, already paid for? There are any number of clever guys in Southern California, and plenty in Dearborn, who could put something together very quickly. I know, I know, separate chassis frames and bodies are so old-fashioned, only clunkers like the Corvette still using them. And there is another clue: Corvette chassis frames are made in both steel and aluminum, hydroformed inside the same tools as far as I know. Could A. O. Smith, manufacturer of the Panther chassis, make the same thing in alloy? Since GM does it, Ford can do it — Ford has made a practice of following GM leads since the days of the fabled Whiz Kids in the immediate post-war period.

The most successful Ford product of the Henry II era was the Mustang, a re-jiggered Falcon that used existing parts to make an imaginative whole. It seems to me that the existing Town Car/Crown Vic platform could easily and cheaply redone with i.r.s., an aluminum engine from existing engineering stocks and a new, optimized body shell in the same way. It wouldn’t be breaking any new ground technically, unless a big effort were made to innovate in the structure of the body, but it would give Lincoln the front engine, rear-drive car it so desperately needs, and with some intelligent styling and engineering it would give Ford most of that taxi and police business it is throwing away with the abandonment of the Panther.

Sure, it’s old. So what? There’s a big market, it’s accessible for not much capital investment, and a suitable set of low-investment products could fatten up the bottom line of the company we all admire for not screwing the taxpayers with a fix-is-in quick-rinse bankruptcy. Ford has the hardware, the designers, the engineers and the need. Does it have the will? Does it have the courage to ignore eventual criticism about using a 32-year-old base for contemporary profits? I say there ought to be a 2013 Town Car, and they ought to get to work on it right now.

Diesel do it

I’ve been intrigued by the idea of diesel engines for cars for a very long time. I was still in high school when the impressive Cummins Diesel Special’s took the pole at Indianapolis in 1952, suggesting a revolution in the making. But it actually took more than half a century before a diesel engine would win a major motor race. Ten years after the Cummins achievement there were two diesels on sale in the US, from Peugeot and Mercedes, both of which liked to claim that they were first to offer production diesels in their home markets, although a Citroën Rosalie wagon preceded them . They were noisy, smelly, slow and tedious to operate: you had to wait for an interminable period (well, actually just a minute, but it felt long) for a glow plug to heat up the combustion chamber so the engine would light off, and when you wanted to stop, you had to pull out a plunger that did something to cut fuel flow.
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In 1968, I spent almost a month driving around Europe in a Peugeot 204 station wagon equipped with a small (1255 cc) high-speed (5000 rpm) 46 bhp diesel. It was still noisy, smelly and slow, but also fairly nimble and certainly extremely economical. That experience led me to write a piece praising the possibilities of diesels in a 1969 issue of Motor Trend, in which I made the controversial suggestion that should diesels ever come in America, they should be in Cadillacs, air-conditioned and fitted with automatic transmissions to hide the fact that diesels did not accelerate well, and were all out of revs very early, requiring a driving technique antithetical to US habits.

During the last ten days or so, I’ve had a crash course in the latest diesel technology, or at least part of it. First was a seminar at the Mortefontaine test track north of Paris, where Renault showed off its latest 130 bhp diesel, a 1600cc four-valve four cylinder engine. It replaces a 1.9 liter engine of the same power, but saves 20% of fuel and almost — but not quite — qualifies for a bonus for low CO2 emissions. The design leader for the R9M project, Philippe Coblence, held the same job at Renault’s Formula One operation when the company developed its championship-winning V-10 engines.

Using only 25% of carryover parts from earlier 2.0 liter fours and 3.5 liter V-6 diesels, the new 1.6 liter, four-cylinder, four-valve DCI 130 engine develops the same power as its 1.9 liter predecesor, weighs no more despite the addition of numerous poullution-reducing accessories, and is both quieter and noticeably better in drivability. Drawing on F1 practice, it is a “square” engine, with more and stroke close to identical, giving more surface area for bigger valves.

Just a few days after driving the Renault engine, I was in Barcelona to try the newest Citroën crossover, called DS 4. A fairly clumsy car intended as a combination crossover-SUV-sedan, it was tuned to be “sporty” in gasoline form, with a rorty exhaust sound that was quite quickly tiring. When my French colleague and I tried the same car with its diesel engine we found it far more pleasant to drive. With the same tire-wheel combination, it had plenty of grip, but we were spared the exhaust noise and the need to change gear as often – the massive torque of the diesel making for a more relaxed but equally quick run. The gasoline engine makes 275 newton-meters of torque between 1700 and 4500 rpm, while the 40 bhp less powerful diesel churns out 340 Nm between 2000 and 3000 rpm.

But the real clincher that diesels are really here as superior automotive powerplants comes from driving a couple of thousand miles in a BMW 530d, a three-liter, 245 bhp diesel that used a lot less fuel than a two-liter Renault I owned a few years ago and used on a similar run in Italy. Driving from Paris to the Dordogne, to Geneva and on to Lago Como, I could set the cruise control at whatever speed I liked and the car would hold it effortlessly. The wind noise was greater than the engine sound, and there was very little of either. The BMW is, thankfully, not Lexus-quiet, but always assures with the subdued sound of well-engineered machinery. To cruise for hours at a legal 82 mph while getting 33 mpg is really satisfying. Knowing that you could push the speed up to 140 mph effortlessly is really reassuring. The same engine, in a different state of tune, is offered in the 535d where it makes 306 bhp, gets to 62 mph in less than 6 seconds and — at least according to BMW France’s PR leader — uses no more fuel in normal driving.

Hybrids, electrics, fuel cells, all the techniques being explored for daily drivers are worthy experiments, but for right-now use, European-standard diesels will beat anything else on American roads. Sure, you can go faster with a supercharged 7 liter V-8, but not legally, not on public roads. I really don’t hold much brief for diesel racing cars now, but I surely am impressed by what can be accomplished with a multi-valve, electronically-controlled, catalyized low-pollution compression-ignition engine in normal sedans, wagons and SUVs.
I just spent a night with a 2011 Cadillac CTS-V wagon, and I can’t help but feel a little grateful. Grateful that Cadillac not only saw fit to launch a five-door version of its latest CTS (along with such an awe-inspiring performance version), but also that the end product was a far cry from the company’s first attempt at a CTS wagon. About a year or so back, I was driving by a GM-owned parking lot in Metro Detroit that was filled with vehicles slated for disposal. Something caught my eye — I thought I saw a first-generation Cadillac CTS, but I also thought I glimpsed an elongated roof and an extra set of pillars. Was I seeing things?

Not exactly. I circled back, and peered through a fence from the safe haven of a sidewalk. Sure enough, tucked alongside other engineering mules and scrapped vehicles was a design mockup for a first-gen CTS wagon.
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The 00-00-00 license plate, coupled with a number of faux trim elements peeling from parts of the car, indicated this spent most of its life within GM’s design studio, and likely never moved under its own power. But the thing was still captivating — not only was it evidence Caddy had considered a CTS wagon before, but a high-riding, butched-up wagon designed to appeal to SUV-loving buyers.

The end result looks a little like an American knock-off of Audi’s not-so-successful A6 Allroad Quattro. In addition to the tall stance and large wheels, designers were apparently also working on adding anodized front and rear skid plates, grey cladding along the rockers, and matching grey bumpers out back.

This all suggests Cadillac was considering adding all-wheel-drive to the CTS line way-back when. That was certainly plausible, considering two other variants of the Sigma platform were capable of delivering power to the front wheels, but it would have been new for the CTS itself. Although the second-generation was (and is) sold in AWD form, the initial model never was.

What I’d like to know is exactly when this idea came about. I can’t help but think this steps closely on the toes of the original SRX, which not only shared its Sigma platform with the CTS, but always felt a little more wagon-like than many of its competitors. I wouldn’t be surprised if this concept was nixed after Audi canned the Allroad in the states, opting instead for conventional SUVs and crossovers instead.

That’s a mystery I may never solve. Few at GM seem to remember the project, or those who do remain silent, apparently in the hope they’ll someday forget. Regardless, the mockup itself is history (literally; it was demolished a week after I shot these photos), but thankfully the idea of a CTS wagon wasn’t so easily dismissed.

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