For the last five months, GM has been putting the battery system of each company to the test in advanced labs. As early as this month, some of the batteries will actually find their way into a specially-equipped Chevy Malibu powered by the Volt's electric motor for a series of real-world tests. We should point out that no fully-operational Volt has been assembled yet, the first such unit being scheduled for 2009.

"We chose lithium-ion batteries because of their high storage capacity and easy use. They also prove much more efficient than nickel-metal or lead batteries. We're still working on the prototype, though, since we've only received and tested six batteries so far," said Lance Turner, battery engineer for the Volt project.

Perhaps as a source of inspiration, an old Saturn EV1 (the infamous electric car which GM killed off in 2000) stood at the back of the lab.


Killer looks?
While batteries remain a primary concern, the other components are pretty much wrapped up. The overall design is nearly completed, although we were only allowed to view part of the car.

"You'll see that we tried to preserve the striking character of the original concept," said Bob Boniface, Director of GM's Advanced Design Studio. He partially took the wraps off one of the clay models in the middle of the room so as to give us a preview of the production Volt.

The front end is very reminiscent of the concept car. The headlights, bumpers and grille are quite similar. On the other hand, the angular front bumper has been made rounder to improve aerodynamics. In the back, the taillights stretch a bit wider, although the overall boxy styling is unchanged.

Sizewise, the new Volt is just as long as the concept and slightly taller to give passengers more headroom. It will be a "hatchback sedan", by the way.

The modern interior design will incorporate new technologies that have yet to be determined. However, we do know that the Volt will offer keyless entry; once the owner approaches the car, the system will automatically unlock the door and "pre-start" the electric unit. You'll have to push a button to make the motor come to life. And since the latter remains dead silent, GM promises that a sound signal will alert drivers that it's on.

The Volt will offer seating for four due to the batteries in the floor and underneath the rear seats.