Aluminum body on F150

BenK wrote:

He told me our TIG was not good enough and authorized the purchase of
a MILLER and high freq stabilizer. Both variable and boy are they
expensive. Cannonade's (bicycle) proprietary TIG and wire feed system
is wonderful, but too much manual labor (hands on...robotics can't
do this well enough)
...
Ditto the paint guys...a VERY expensive learning process when the
customer's QC guy told us the paint hadn't adhered correctly

Am not up on laser welding, so another thing to bone up on when time
permits. Know enough about laser cutting, but to weld...the modulation
must be very, very good...wonder if they are as good as our controllers
back in the 60's through 80's???

Ben, with all due respect how do you think people originally learned how to weld steel? It was through trial and error, just as it will be for Ford. The process and equipment required to weld aluminum will improve as the demand for improved equipment grows.

Do you remember the auto industry BEFORE robotic welders? They are relatively new to the industry. I'm sure the first company that planned to use robots faced the same backlash... guess what, they eventually figured it out. I'm sure that Ford (and others) will eventually figure out how to use robots to weld aluminum.

The same can be said for all the issues that you mentioned. At one point we didn't have any of that technology. Through innovation we now do.

What if the industry decided against air bags because we didn't have an established record of using them?
What about variable valve timing?
What about direct injection?
What about overhead cams?
What about anti-lock brakes?
What about fuel injection and modern computers?
What about air conditioning?
What about power locks and windows?
What about headlights and taillights?

I think it is hilarious that we live in an age that is defined by all the modern conveniences that we take for granted. We appear to have zero regard for the fact that even a few short years ago we didn't have these luxuries, and we only have them because some innovator had an idea and took the risk.

Every generation seems to feel that all the innovation is done and things are fine just the way they are. We've never done "X" before so we shouldn't try and its stupid and its going to fail. Then in a couple years when "X" is the norm we will complain that "Y" is too expensive and is increasing our costs. But a couple years down the road we will demand that "Y" be in every vehicle.

My dad used to HATE power windows and locks. He would complain its just another thing to break. Initially he was right. He would only buy cars with manual window cranks... even into the 90's. Now he has a car that will automatically roll the windows down from his key fob on a hot day.

Its amazing the technology that we hate and fight against... and then we cannot live without in such a short period of time.

Maybe aluminum isn't the answer. It sure seems like a substantial investment for minimal gain, but I prefer to wait until I have evidence one way or the other before I jump on the bandwagon. Maybe this is the answer, maybe its not. I, for one, am thankful that auto companies are trying to be innovative and give us a better vehicle all the time. Otherwise we would all be driving 40 HP model A Fords and the only available color would be black...