BJC: while it's important to look carefully at the lifecycle costs of assembled systems like cars, such calculations are also somewhat subjective and hence easy to manipulate.
The basic economics tell much about the various costs involved in producing these vehicles. Of course, such a comparison is only valid for vehicles which actually exist in production and for which fuels are available at retail, i.e. unlike PEM fuelcell vehicles etc.
Let's compare the Prius hybrid 5 seater to the Toyota Yaris, a 4 seater subcompact. Prices are $US, but with Canadian current fuels cost ~$1CDN/L.
The Yaris MRSP is about $12,000.00. Fuel economy is 34/40 mpg highway/city. Over a lifetime of 300,000 km (186,000 miles), the Yaris will consume about 5,000 gallons of fuel costing, say, $16,500.00. It produces about 156 pounds of smog-producing emissions during that life per USEPA.
The Prius, a somewhat larger vehicle (96.2 cu ft vs 84.6 cu ft), MRSP is about $22,000.00 (nearly double the Yaris). The price is apparently subsidized somewhat by Toyota, but we don't know exactly how much. It consumes about 3,400 gallons or $11,000.00 worth of fuel over the same lifetime, and produces less than half as much smog-producing emissions (72 pounds).
The difference in purchase price (~$10,000) is roughly double the difference in fuel cost (~$5,000), and won't pay back without significant subsidy, or unless fuel prices rise dramatically. It is conceivable that the Prius's purchase price may actually contain some embodied energy difference which may explain part of this fact- but I'm also sure that some of the purchase price difference is labour, not embodied energy.
Compare the Prius with a somewhat larger compact, the Matrix- probably a fairer comparison. $16,000.00 MRSP, 5,900 gallons or ~ $19,000 in fuel cost. Now the difference in fuel cost pays back the entirety of the difference in purchase price, forgetting about the time value of money- or the fluctuation in fuels pricing.
Unless the subsidy on the Prius is very significant, there's no way there's more DIFFERENCE in energy content (to make and transport the hybrid system's batteries etc.) between the Prius and the Matrix to make the Prius significantly worse in energy consumption LIFECYCLE terms than the Matrix. The money's not there to justify such a supposition at current pricing.
Note also that most of the materials in both vehicles can be recycled, including the Prius's batteries. Unlike the gasoline these vehicles consume, most of the nickel doesn't go anywhere- and it takes a fair bit less energy to recover nickel from a Ni-MH battery than from nickel laterite or sulphide ore. So going to the Sudbury mine, one that's been in production for over a century and is over a mile deep, is a bit disingenuous.