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Tesla Has Room to Grow With the Model S Sedan, Calif. Factory

By Mark Vaughn

By AutoWeek Oct 4, 2011 10:31AM

Tesla plans to sell 20,000 copies of the Model S sedan per year. (Photo by AutoWeek.)




We got a brief ride in a prototype of the Tesla Model S all-electric sedan, and as far as we could tell from the passenger seat, it seemed like a luxury performance bargain for just $57,400. Of course, being just a passenger means any evaluation is more or less just a guess.


We should get to drive one of them sometime before the fully finished models go on sale next summer and then we will have a more definitive take on the car. But for now, so far so good.


Before we even crawled inside, we liked the look of the four-door hatchback, all svelte lines and subtly flowing fenders. It seems to blend the best elements of Aston Martin and Jaguar with those of BMW and Maserati. The hybrid electric Fisker Karma might be the only car that can compete with it in terms of cool cachet and eco chic (there's a banana-leaf dashboard!).


The passenger seat in which we sat offered plenty of space all around, much more so than, say, in a Rapide. The back seat was full-size, too, better than that of a Mercedes-Benz CLS.


The digital instrumentation reduced clutter behind the steering wheel while the 17-inch touch screen in the center console will impress owners of plasma televisions. Even the door handles operated with a technological elegance not seen outside of a Bond movie--touch them and they extend out toward your hand to be opened.


We had to remind ourselves that the drivetrain is as unique as the rest of the car. The fact that it's all electric seemed almost an afterthought, as this shape could fit in with any of the best luxury cars offered today.


When they wheeled the first one up next to a large group of visitors outside the Tesla factory in Fremont, Calif., there were those who didn't even notice its arrival, so stealthy is the car's near-silent electric drivetrain. The powerful AC induction motor provides 306 lb-ft of torque from zero up to 7,000 rpm. The inverter, motor and single-speed reduction gearbox are all packaged between the rear wheels. With no motor up front, there is greater opportunity to design in perfect balance, especially considering that the battery case is a huge, flat rectangle bolted directly under the bottom of the car.


The body is all aluminum. The weight of the body-in-white and curb weight of the finished car were not available to us, at least not from any of the executives we spoke with. Even the weight differences of the three available battery packs--which provide driving range of 160 miles, 230 miles and 300 miles--is still being sorted out.


Our ride consisted of a short slalom, a quick launch and a few laps of the tightly banked test track on the factory grounds. We're guessing, but was that understeer in the slalom? The car felt a little heavy, not as tossable as a BMW 5-series and perhaps set up with a spring/shock combination we would have tweaked just a bit for softer jounce and easier rebound. How much can you guess from a few minutes in the passenger seat in a parking lot? Suspension tuning on this Beta prototype is supposed to be 80 percent there, but it's not by any means finalized. Maybe if they'd let us drive we could have gotten a better feel for it all.


Acceleration certainly felt more than adequate. The standard Model S is supposed to get to 60 mph in either 5.4 seconds or 5.6 seconds, depending on whom you ask, and there will be a performance version that can unleash a 4.5-second time. We look forward to driving a production version ourselves.


Just as interesting as the car was the factory in which it will be built. Tesla bought the old New United Motor Manufacturing Inc. plant from the defunct General Motors/Toyota joint venture for $42 million. Another $17 million got Tesla tons of leftover machinery inside. Then Toyota bought $50 million in Tesla stock, in effect giving Tesla miles and miles of assembly line and millions of dollars worth of machinery for pretty much next to nothing. (There are other ways to look at the transaction, but that's our take.)


Tesla gave us a tour of the sprawling facility and we found most of it is empty. You don't need as much machinery to produce 20,000 Teslas a year as you do to crank out millions of Geo Prizms.


So the most impressive thing about the Tesla factory is the empty space. You could hold the 24 Hours of Le Mans full-scale indoors here. Even the parts Tesla is using offer huge swaths of factory floor--all newly painted--between each of the machines. They use strand cruiser bicycles and razor scooters to get around inside. It's like a starter kit-car factory from Mattel.


But we met many of the principals and saw where all of the work is going to be done, and by golly, they might just pull this whole thing off! Now, the only thing left is for 20,000 people a year worldwide to buy a luxury electric car. With the price of gasoline continuing to rise, increasing environmental concern among an increasingly larger segment of buyers, and with government regulations worldwide demanding ever-cleaner cars, Tesla could be positioned in just the right spot at just the right time. With plenty of room for expansion.


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18Comments
Oct 7, 2011 8:03AM
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Tesla currently has 6600 vehicles pre-sold.  That translates to 350+ million dollars in revenue.  At the event a guy from Iceland placed an order for 100 vehicles for a car sharing program.  They have already hired over 1000 people to produce this car.  They have bought an unused manufacturing plant.  They have an innovative vehicle that is 80-90% complete and are on schedule to release it next year.  All for the paltry LOAN of 450 million.  I'd say thatwas money well spent.  This is an American company that has Toyota and Daimler giving them money for assistance with their vehicles. 
Oct 6, 2011 7:10AM
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An all electric Maserati? No wonder Toyota buy so much of their stock. Tesla got it real good. This  comes out and the competition might get real fierce in the EV market.
Oct 9, 2011 7:24AM
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Hefman the batteries are recyclable and depending on what kind the use may not even be toxic. So that point is pretty much moot. Now as far as the electricity goes, it can come from any source. Wind , solar, nuclear, natural gas fired, or coal burners. Also when the technology catches up it will likely be able to be converted to a fuel cell and burn hydrogen. So I'd say even though they aren't perfect that these cars are a vast improvement from the environmental  standpoint.
Oct 9, 2011 2:46PM
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TESLA will rock the auto industry once model S releases, Im getting one for sure!
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It  is about time that someone at home is thinking big and clean. Because elegance and power do not mean just gasoline... to all.
Oct 10, 2011 10:03AM
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Well done America. Lead don't follow. Tesla is a company that will change the automotive landscape in much the same way that Ford did. 

My only gripe is that the Tesla Roadster will no longer be produced after the S goes into production. Hopefully they will build another sportscar to fill that hole.

Oct 12, 2011 1:37PM
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Battery Question:   Admittedly I'm off in the intellectual weeds with this, but if you live in a part of the country with lots of sunshine, is it possible to use a solar array on your roof, or nearby, to charge this thing.  I also realize the economics may be ridiculous, but whaddya think?  Some of you know lots more about this than I ever will, but the Tesla could be a good primary vehicle for my wife and me.  We frequently travel together during the day, and usually not for extended distances.  Sounds like maybe we're heading in the right direction regarding electric vehicles......MADE in the USA.

Oct 9, 2011 7:54PM
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First its a beautiful car & its driving everyone crazy because they are showing you how other companies gauge the consumer. They are using all new tech to power the vehicle so it should cost more right? well it is half of the cost of the cars they compete against. 
True the batteries & yes where ever your electric company gets there power is how you get yours.
In Texas we have wind options so no all of them will not run on coal Tongue out Buy solar panels &power your own.
Do more research and also learn that if you convert the waste for gas vs. elec it is twice as efficient with the power consumed so it still wastes less. The only problem that is still being bettered are the batteries. there are a lot more in number but they are a lot better than they were even 5 years ago & when people buy more they will get better literally every year
Oct 10, 2011 3:34AM
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The only problem that is still being bettered are the batteries. there are a lot more in number but they are a lot better than they were even 5 years ago & when people buy more they will get better literally every year
So literally, buying something makes it "bettered?" Glad that's settled then.
Feb 10, 2012 6:00PM
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I agree fully with going American..... but a concern that I would have is Toyota scrambling in the door. Are they trying to help it along or are they angling for a takeover in the future. Will it remain American. Call it what ever you may want. I think it is a great piece of American know how and a huge stride in the right direction. Congrats to Tesela
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