The reality of aluminum body panels.

[fordmantpw]

My insurance company (AAA) bases premiums in part depending on what it costs to repair a vehicle.

I'm pretty sure all insurance companies do that, but there is a lot more to it than that, though that is but one of hundreds of variables that go into it. I worked on rating software for an insurance company 15 years ago and I was amazed at the different parameters that go into factoring rates.

 

[fordmantpw]

For those on the negative side of things, you really need to read this if you are truly interested in the truth and not just interested in making Ford look bad. Basically, the Edmunds test was 'erroneous.'

Real Cost of Repairing an Aluminum-Bodied 2015 Ford F-150 - Consumer Reports

However, Consumer Reports’ own analysis shows that the aluminum parts on the F-150 cost about the same as steel parts on last year's truck, and because the new F-150 is designed to make replacing panels easier, in many cases labor charges may be lower.

Generally, Consumer Reports' data shows that independent repair shops score better in our service satisfaction survey. But in the case of specialized work such as this, we recommend you go to a certified dealership. If you decide to go to an independent, make sure Ford has certified them as well.

Insurance companies seem to agree. Our research has also found that owners of the new aluminum truck aren’t being charged more for collision insurance than the outgoing model.

The jury is still out on what ownership costs will be in the long run, but thus far, repair costs seem to be in line with the previous-generation model.

 

[Ford850]

For those on the negative side of things, you really need to read this if you are truly interested in the truth and not just interested in making Ford look bad. Basically, the Edmunds test was 'erroneous.'

Real Cost of Repairing an Aluminum-Bodied 2015 Ford F-150 - Consumer Reports

That was interesting. This Consumer Reports story is the second one I've read where they poked holes beginning to end in how Edmunds did there test. This is also being discussed on the GM boards, and most posts over there look at the Edmunds story as bogus. If you read the full 3 parts of the Edmunds story (not the Forbes take on it) it becomes obvious they slanted it in many ways, looking for big numbers. And then had to speculate to get numbers they hoped for. You'll notice that Edmunds has nearly a 1 1/2 million hits on the first video already, and nearly 1/2 million on the part 2 video. "Erroneous" makes them some easy money.

 

[fordmantpw]

That was interesting. This Consumer Reports story is the second one I've read where they poked holes beginning to end in how Edmunds did there test. This is also being discussed on the GM boards, and most posts over there look at the Edmunds story as bogus. If you read the full 3 parts of the Edmunds story (not the Forbes take on it) it becomes obvious they slanted it in many ways, looking for big numbers. And then had to speculate to get numbers they hoped for. You'll notice that Edmunds has nearly a 1 1/2 million hits on the first video already, and nearly 1/2 million on the part 2 video. "Erroneous" makes them some easy money.

Bingo! I tried to say that 115 posts ago!

A snippet of my post #106 (I just noticed I spelled by wrong too. ):

Edmunds wanted to draw traffic to their site, and that they did. Buy using a bunch of hypotheticals to support their hypothesis.

 

[ray66v]

Its easy to unbolt a hood, throw it out and put a new one on. Its not so easy to do that with a door skin or quarter panel.

I am very confident in thinking that, if the door is made the same way as a traditional door, you will not be able to replace the skin on an aluminum door.

You will have to replace the entire door. Which always has, and always will, cost a lot more than an outer panel.

 

[ray66v]

How is that different than today with the F150 and Mustang (and other vehicles I am sure) having an aluminum hood? Do they just replace them or have that part repaired elsewhere?

No, they do repair them sometimes, generally improperly.

Aluminum parts are replaced far more often, than the same part made out of steel. Because, it is not generally as repairable, when it's bent.

You are supposed to take the temper out of them first. And, at minimum, tape up your hammer faces, and dollies. And, not not use the same grinders, and sand paper during the repair. to avoid cross contamination. I am not sure how often that all happens. But, I am certain a lot of guys don't.

They are not structural parts either.

High end cars, that have all aluminum bodies, are generally sent to dedicated, sometimes even factory repair facilities, hundreds of miles away, when they need structural repairs.

 

[TomSeller]

In the days of recycling, I don't know why they repair panels anyway. It often is more cost effective to buy a new engine than rebuild an engine. Seems it would be similar in panels.

 

[TomSeller]

Its easy to unbolt a hood, throw it out and put a new one on. Its not so easy to do that with a door skin or quarter panel.

That depends on how they were manufactured.

 

[ray66v]

In the days of recycling, I don't know why they repair panels anyway. It often is more cost effective to buy a new engine than rebuild an engine. Seems it would be similar in panels.

The reason we repair panels, is the same as it has always been. 98% of the time, we repair panels, when it costs less to repair it, than replace it.

Insurance companies are not concerned about recycling, efficiency, or if we even make a profit. They are very interested in what will cost them less in the end.

 

[crazyal]

The repairs are going to be different than steel. With Aluminum you're not going to just pound out a dent. What this means is small dents could cost more to repair than on steel. Larger dents that require the panel to be replaced probably will not cost much different. I personally believe that Ford is eating the extra cost of the aluminum panels to keep costs as comparable to steel as possible. Things that are going to cost a lot more will be structural panels. Things like the support for the fenders, door pillars, etc. They would just be pulled straight if made from steel. With Aluminum they will need to be replaced which will require a lot of work to remove everything attached to and around the panel to be removed. Don't forget the whole panel will most likely need to be replaced. Rolling an aluminum cabbed truck on it's side could mean the whole cab needs to be replaced. I would say the jury is out for at least a year or so. By then insurers will know the real cost of aluminum on a large scale.