The reality of aluminum body panels.

[fordmantpw]

My impression is, that only the outer panels are aluminum, the inner structure, i.e. cab, bed floor, is still steel on these?

No, the inner structure is all aluminum as well, with the exception of the firewall. Supposedly, the 'quiet steel' does a better job of dampening noises than aluminum so they left it steel. There is an image showing just what is Al and what remained steel. I will try to find it...

BTW, the frame is still steel.

Here is one image. Not what I was looking for, but I will see if I can find the other one.

 

[ray66v]

No, the inner structure is all aluminum as well, with the exception of the firewall. Supposedly, the 'quiet steel' does a better job of dampening noises than aluminum so they left it steel. There is an image showing just what is Al and what remained steel. I will try to find it...

BTW, the frame is still steel.

Here is one image. Not what I was looking for, but I will see if I can find the other one.

View attachment 410198

Okay, well that inner-structure is going to be a while different ball game.

I would be surprised if any of that stuff is glued.

Most of the time it was only me an another guy carrying them, so I sure would have rather carried my side of an aluminum pick up bed in and out of the spray booth, instead of a steel one.

 

[fordmantpw]

Okay, well that inner-structure is going to be a while different ball game.

I would be surprised if any of that stuff is glued.

On the other hand, I sure would have rather carried one side of an aluminum pick up bed in and out of the spray booth, instead of a steel one.

I'm not sure on how much of that is glued and riveted, but I do know there is extensive use of glue and rivets throughout the truck. I couldn't find the other image and can't remember where I saw it, but this gives you the basic idea.

 

[ray66v]

I'm not sure on how much of that is glued and riveted, but I do know there is extensive use of glue and rivets throughout the truck. I couldn't find the other image and can't remember where I saw it, but this gives you the basic idea.

We were never allowed to use glue on structural parts, in the past.

Thanks for the info.

 

[HHR]

The 2015 Ford F-150 average transaction price in January was $51,354.
If people are paying this much for a half ton truck, I doubt they will notice their insurance premium going up $20 a month due to aluminum.

 

[JDgreen227]

I just read an article about the new Ford F-150 in the March 2015 issue of CONSUMER REPORTS and this is a direct quote from it:

"Ford claims that body-repair costs won't be any higher than those for a steel-bodied truck....."

 

[piercedtiger]

The 2015 Ford F-150 average transaction price in January was $51,354.
If people are paying this much for a half ton truck, I doubt they will notice their insurance premium going up $20 a month due to aluminum.

Someone like me going from just comp to full coverage again would probably have a hard time seeing $20 extra in the price jump due to aluminum anyway.

 

[ray66v]

I just read an article about the new Ford F-150 in the March 2015 issue of CONSUMER REPORTS and this is a direct quote from it:

"Ford claims that body-repair costs won't be any higher than those for a steel-bodied truck....."

Of course they are going to say that. :laughing:

The insurance companies are also going to make every attempt to see that happen.

The first problem is, there will be a limited number of places who will have the equipment, and the training to repair these. When there is a shortage of anything, the price goes up.

I have taken structural aluminum repair certification classes. They called for all the tools, and and equipment, used in the repair of aluminum to be dedicated to that, and kept separate from the tools, and equipment used in the repair of steel vehicles. Specifically, they recommended these repairs be done in a separate area, or facility. By technicians who are specifically working on only an aluminum vehicle.

This is because, working with steel all day in a body shop, creates tiny metal particles that can, during hammering, clamping, gluing, or just falling off of the technician, who just finished grinding some steel, can be impregnated into, or left in contact with the aluminum sheet metal. Which of course, leaves the possibility of corrosion.

If that investment is what actually ends up being required to repair these, that will also limit the number of facilities that will be able to do this type of repair.

The welding of aluminum, is a specialized skill. Since, it was never needed in a traditional body shop, few body technicians have acquired those skills. Since, lives depend on structural welds, time will be needed for them to develop those skills.

Somewhere way down the road, when all this is common, and everyone can fix them, it is much more likely it will not cost more for the labor end.

The parts will cost more to produce. And, anyone who believes that will not equate to higher prices, is not familiar with the level of greed manufacturers have shown in the past, with respect to crash part prices.

 

[JDgreen227]

Of course they are going to say that. :laughing:

The insurance companies are also going to make every attempt to see that happen.

The first problem is, there will be a limited number of places who will have the equipment, and the training to repair these. When there is a shortage of anything, the price goes up.

I have taken structural aluminum repair certification classes. They called for all the tools, and and equipment, used in the repair of aluminum to be dedicated to that, and kept separate from the tools, and equipment used in the repair of steel vehicles. Specifically, they recommended these repairs be done in a separate area, or facility. By technicians who are specifically working on only an aluminum vehicle.

This is because, working with steel all day in a body shop, creates tiny metal particles that can, during hammering, clamping, gluing, or just falling off of the technician, who just finished grinding some steel, can be impregnated into, or left in contact with the aluminum sheet metal. Which of course, leaves the possibility of corrosion.

If that investment is what actually ends up being required to repair these, that will also limit the number of facilities that will be able to do this type of repair.

The welding of aluminum, is a specialized skill. Since, it was never needed in a traditional body shop, few body technicians have acquired those skills. Since, lives depend on structural welds, time will be needed for them to develop those skills.

Somewhere way down the road, when all this is common, and everyone can fix them, it is much more likely it will not cost more for the labor end.

The parts will cost more to produce. And, anyone who believes that will not equate to higher prices, is not familiar with the level of greed manufacturers have shown in the past, with respect to crash part prices.

EXCELLENT POST, well composed and informative. Thank you for your contribution to this thread.

 

[fordmantpw]

The first problem is, there will be a limited number of places who will have the equipment, and the training to repair these. When there is a shortage of anything, the price goes up.

I have taken structural aluminum repair certification classes. They called for all the tools, and and equipment, used in the repair of aluminum to be dedicated to that, and kept separate from the tools, and equipment used in the repair of steel vehicles. Specifically, they recommended these repairs be done in a separate area, or facility. By technicians who are specifically working on only an aluminum vehicle.

This is because, working with steel all day in a body shop, creates tiny metal particles that can, during hammering, clamping, gluing, or just falling off of the technician, who just finished grinding some steel, can be impregnated into, or left in contact with the aluminum sheet metal. Which of course, leaves the possibility of corrosion.

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?