Ford Transit Van

Handbasket wrote:
Just to add fuel to this debate, the last I read said Ford is coming out with a new F-150 if 2015. That's been the 'crown jewel' of the Ford line for decades in terms of sales volume; they don't make fundamental changes in that design without giving it a lot of thought. The cab will be made of _aluminum_ instead of steel, for a reported overall weight savings of 750 lbs. It's unclear to me if that's just the cab weight, or includes other components that are lighter because they have to carry less weight.

If this works out, the changeover to AL on other of their high-volume vehicles can't be far behind. I wonder how long it'll be for the Transit?

My limited understanding of aluminum sheet metal says that you must redesign the stamping dies entirely. It has more 'springback' that steel, so requires more 'over-bending'. This implies a new generation of design, since you're unlikely go to that _huge_ expense just to change material. It also requires more energy to weld, since it transmits heat faster. Of course, they could probably use adhesive bonding for a lot of the joints.

I'm wondering if the current Transit will be relatively short-lived, in the face of this. At a wild guess, a high-top long van might see a weight savings of 1500 lbs or more if changed to AL. That'd toss the fox in amongst the chickens.... ;)

Jim, "Mo' coffee!"

Jim, the whole truck body, including hood, fenders, cab and bed are going to be aluminum. Having worked in GM assembly plants for 34 years, all I can say is they are going to have a heck of a time with these in paint prep, and taking care of the body as it goes through the assembly process. LOTS of more difficult & time consuming, (think body shops & insurance rates), repairs will happen in the plant and on the street.

The thing is, the press, (Ford marketing strikes again), is making such a big deal of this change, which I'll admit is a big material change, but the weight savings still makes the Ford only 200 lbs. lighter than GM's new line of pickups, 2014 on up.....

My opinion is the Transit won't see much aluminum until way later down the line. Maybe hoods, fenders sooner?? And they may already be with this generation, dunno