Chevy Volt to Get 230 MPG. We Take a Tester Out for a Spin.

We‘ve all known that coming plug-in hybrids and extended range electric vehicles (E-REVs) like the Chevy Volt will offer pretty amazing fuel efficiency, possibly into the triple digits. But 230 miles-per-gallon? That figure – just discussed for the first time by the resurgent General Motors – is the projected fuel economy of the production Chevy Volt, based on development testing using draft EPA fuel economy methodology for plug-in electric vehicles. This methodology assumes plugging into the electrical grid to charge up at least once daily.

Actually, many drivers will get even better fuel economy, hard as that may be to imagine. Department of Transportation studies show that 80 percent of American drivers commute less than 40 miles per day. Since the Volt will have a 40 mile all-electric range, that means gasoline may never be required. Longer trips driven on electric power sourced from the grid for the first 40 miles, supplemented by electricity created by the Volt’s small and efficient engine-generator, will bring ethereal fuel economy numbers up to the projected 230 mpg rating, depending on the length of a trip and how much gas is used to generate on-board electricity.

What’s it like to drive this kind of mega-efficient car? Since the 2011 Volt is still somewhat over a year from its market introduction, it’s a bit early to be driving pilot production vehicles. But Green Car can share early impressions derived from seat time in a Chevy Volt test mule. Test mules are existing model platforms that are often equipped with an upcoming vehicle’s advanced technologies to allow experiencing their characteristics on the road. Green Car editors have driven many test mules over the years including those for the GM EV1 in 1992 and the Toyota Prius in 1995.

Our opportunity to experience the Volt’s technology came at the GM Tech Center in Warren, Michigan. With gray skies overhead and enough rain hitting the windshield to cycle the wipers, we headed out of the center’s garage with little fanfare. But we knew this was a most significant test drive since the European spec Chevy Cruze test mule we were driving had the underpinnings of a game-changing vehicle … not just for GM, but for the entire auto industry as well.

The overall size and weight of the Cruze closely match the much-anticipated Chevy Volt, so it has replaced the first generation Chevy Malibu as a test mule platform for the Volt development program. The Volt team gutted all the powertrain components from the car, grafted the ‘T’ shaped Volt battery pack into the body structure, and installed the latest generation Voltec powertrain.

From behind the wheel there was no mistaking that this was an engineering vehicle. The large red kill switch mounted atop the dash provided a constant reminder that this test mule was all business. Our experience allowed us to sample the electric powertrain only, with this phase of testing focused on sorting out drivability issues and overall performance of the electric drive system, along with battery endurance. The next generation of test mules will be hand-built Volt body prototypes that will include testing operation of the car’s range extending internal combustion generator.

So how did it drive? Surprisingly well, considering GM is still in a relatively early phase of the development process. Power is supplied from the 16 kWh battery pack to a 149 horsepower electric motor driving the front wheels. Volt engineers project 0-60 mph acceleration of 8.5 seconds, which is quite respectable considering the Volt’s intended mission. We had the chance to pin the accelerator — forget the term ‘gas pedal’ — to the floor from a dead stop and the mule launched with authority, thanks to immediate torque from the electric motor and silky smooth power delivery. The single speed transmission has two forward drive settings. In addition to drive, there’s a second notch that provides more aggressive regenerative braking on coast-down. This worked well in city driving situations, minimizing braking and maximizing regeneration of electricity.

Our time behind the wheel of the Volt mule left the impression that GM is well on the way to bringing this landmark vehicle to production on schedule. Be assured that Green Car will bring you all the latest Volt developments as they unfold.