Steel and Aluminum body panels and construction

[SkyKing]

Sounds like the doors are fairly light which suggests aluminum sheet metal. Generally I am for more aluminum. Has anyone heard the extent to which Ford is using aluminum in the sheet metal for the Bronco? I'm hoping for more aluminum because I live in New England with salted roads, but I also know that body work on Aluminum is expensive and there is a shortage of people who know how to do it and have the equipment (in comparison to steel) - which adds to costs. Blah blah blah.... thoughts?

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[Rusty Sheckleford]

Yes, the Bronco is supposed to be aluminum rich, though not to the extent that the F150 is.

 

[ZackDanger]

https://www.bronco6g.com/forum/thre...erials-construction-on-2021-ford-bronco.3298/

 

[PrepVet]

I’m very concerned about this because the last 2 Fords I have bought have had massive oxidation issues with their aluminum panels.

I had a white 2013 Explorer that had such bad oxidation bubbles and peeling paint it looked like it was a sun baked 80’s GM car. I traded that in for my current red 2015 Expedition EL and the bubbling and cracking is horrid as well.

I live in Northern Wisconsin so I get the salt and sand and brine on the roads a lot but I also wash my cars regularly and keep them in the garage.

I like using Al where you can but I am not happy so far with what I have seen Fords level of ability to paint it is at.

 

[Raptor.Tremor.Bronco]

I’m very concerned about this because the last 2 Fords I have bought have had massive oxidation issues with their aluminum panels.

I had a white 2013 Explorer that had such bad oxidation bubbles and peeling paint it looked like it was a sun baked 80’s GM car. I traded that in for my current red 2015 Expedition EL and the bubbling and cracking is horrid as well.

I live in Northern Wisconsin so I get the salt and sand and brine on the roads a lot but I also wash my cars regularly and keep them in the garage.

I like using Al where you can but I am not happy so far with what I have seen Fords level of ability to paint it is at.

Neither of those were aluminum. I'm pretty sure

 

[Raptor.Tremor.Bronco]

Does anyone know about the inner structure materials? Such as the fender aprons, inner quarter panels, pillars, etc.

 

[PrepVet]

Neither of those were aluminum. I'm pretty sure

Except they were. It was their hood and tailgate.

 

[Stampede.Offroad]

...but I also know that body work on Aluminum is expensive and there is a shortage of people who know how to do it and have the equipment (in comparison to steel) - which adds to costs. Blah blah blah.... thoughts?

Most bodywork cost these days comes down to labor, not materials. That's why Ford has been designing their trucks with more quickly and easily removed panels. The last report I read actually said common repair costs were down compared to older steel part designs.

I would expect the modularity of Bronco design to take that even further. The part might be more expensive, but if you're paying for labor the overall cost should be reasonably low.

 

[Raptor.Tremor.Bronco]

Except they were. It was their hood and tailgate.

Oh

 

[Tricky Dick]

Neither of those were aluminum. I'm pretty sure

Ford has had aluminum hoods for actual decades now. My 04 F150 has just an aluminum hood and there's not a speck of rust on the entire body, but the hood has bubbles. Rock chips are the devil for aluminum.

 

[Raptor.Tremor.Bronco]

Ford has had aluminum hoods for actual decades now. My 04 F150 has just an aluminum hood and there's not a speck of rust on the entire body, but the hood has bubbles. Rock chips are the devil for aluminum.

I've had an 06 since new and never even knew that. Interesting

 

[VoltageDrop]

I’m very concerned about this because the last 2 Fords I have bought have had massive oxidation issues with their aluminum panels.

I had a white 2013 Explorer that had such bad oxidation bubbles and peeling paint it looked like it was a sun baked 80’s GM car. I traded that in for my current red 2015 Expedition EL and the bubbling and cracking is horrid as well.

I live in Northern Wisconsin so I get the salt and sand and brine on the roads a lot but I also wash my cars regularly and keep them in the garage.

I like using Al where you can but I am not happy so far with what I have seen Fords level of ability to paint it is at.

Can you post a picture to show what this looks like? We don't do snow around here so maybe that's why I've not noticed these issues. My 05 F150 had an aluminum hood and core support (maybe fenders too?) and after 15 years I noticed no paint issues.

 

[Hopeless Diamond]

https://www.bronco6g.com/forum/thre...ke-ford-reconsider-its-aluminum-trucks.10593/

 

[PrepVet]

Can you post a picture to show what this looks like? We don't do snow around here so maybe that's why I've not noticed these issues. My 05 F150 had an aluminum hood and core support (maybe fenders too?) and after 15 years I noticed no paint issues.

These are of the Expedition. It is far worse under the wrap around lips and seams. I don’t have any handy of the old Explorer as that was traded in long ago.

 

[Raptor911]

I rather have aluminum. My GEN1 Raptor was 6200 pounds. My GEN2 Raptor is 5700 pounds due to the use of aluminum.

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