Miles to Go

Another quick way to improve fuel economy—and chase away customers—is to strip out stuff that makes the ride comfortable. For example, engineers could remove the soundproofing material that keeps road and engine noise out of the cockpit. Back in the '90s, when Detroit was fond of noting that gasoline was cheaper than bottled water, Hillebrand worked on the popular Chrysler minivan. They were having problems making the cabin quiet, so they sacrificed mileage to add sound insulation. "We just sprayed penny a pound asphalt into it to quiet it down because that was what the customer wanted," recalls Hillebrand. "Another mile per gallon would not make Car and Driver headlines. But having no wind noise did."

These days, though, more mpg makes news. And GM has certainly been getting plenty of mileage out of the Chevy Volt plug-in electric car it hopes to have on the market by 2010. On Thursday, they took reporters inside their Volt lab for another in a series of updates--unusual for a work in progress. And next week, GM will conduct a global online discussion with journalists to address the question: "Why don't automakers produce a 100mpg car?"

So when I called to ask why there are no 50mpg cars, Volt chief engineer Frank Weber practically scoffed at me. "Fifty miles per gallon is not the target," he said in his German accent. "We are working in the three-digit range." All hype aside, analysts say GM just might be the first to achieve 50mpg with the Volt, which Weber assured me will get well over 100mpg. Crackling with confidence, he "guaranteed" the car's advanced lithium-ion battery is ready for the road. Many automakers are racing to develop lithium-ion batteries (like those used in laptops), which juice up faster and go farther on a charge. But only GM is claiming to have cracked the code. Weber also said there is "no doubt" the Volt will deliver on GM's promise of driving for the first 40 miles on pure electric power. After that, a tiny engine kicks in, but only to recharge the battery, not to turn the wheels like conventional hybrids. "Our goal," says Weber, "is to avoid the usage of gasoline completely."

Wouldn't that be nice? But at what price? Analysts predict the Volt will top $30,000, and consumers might have to pay an additional $100 to $200 a month to lease that advanced, but unproven, battery pack. Weber dismissed battery leasing as "an old idea," but declined to divulge pricing on the Volt so far from its launch. Any new technology like this, though, comes with a hefty premium, which takes years to pay off in savings at the gas pump. So taking the high-tech road to high mileage comes down to a question of pay now or pay later. (In the case of some high-priced hybrids, like the late and not-so-great Honda Accord hybrid, the payoff never came.)

In the end, what I found most fascinating about raising this 50mpg question is just how nervous its made Honda and Toyota. Honda wouldn't even speak to me about it. Perhaps that's because Honda has a Prius competitor in the works that it has promised will have better mileage when it hits the road next year. Let's see, what's better than 48mpg? And Toyota is in the midst of creating an entire lineup of Prius models, which will include a wagon, a family car and a tiny urban runabout beginning in 2010. So if you take the Prius power plant and put it into a Smart-size car, what do you get? Toyota isn't saying, but there could be a hint in Reinert's assessment of Mercedes's mighty mite. "The Smart is incredibly attractively packaged," he says. "It could be the iPhone version 1 of cars." Version 2.0 could roll into a Toyota showroom in a few years—with a window sticker well above 50mpg. And not a moment too soon.

© 2008