News

Ford Adds a Hatchback Model to North American Fiesta Lineup

5 Comments 30 May 2008

Ford will build all the Fiesta models in Mexico, sell the cars here in North America

By Brendan Moore

05.30.2008

Automotive News is reporting that Ford has pulled the trigger on selling a hatchback model of the Fiesta sub-compact that is due to appear in North America in 2010.

The Fiesta name hasn’t been used on a Ford car in North America since 1981, when the German-built Ford Fiesta hatchback was sold here. The nameplate has been in use in the rest of the world since that time.

Ford has been wrestling with whether to sell a hatchback version of the car in North America, and now has apparently decided that the upside to doing so outweighs the downside. Ford has been wary of selling a hatchback in the U.S. since many American buyers tend to hear “cheap” when they hear “hatchback”. Witness the fact that the Ford Focus is sold in the U.S. currently only in sedan form, despite the fact that everyone else in the world loves the hatchback style.

But, Ford has determined that there is a future for the hatchback bodystyle in the small car segment, despite its recent travails. Our sources tell us that the following data tilted towards offering a hatchback in the Fiesta:

- Other manufacturers are doing well with the configuration. The Honda Fit, VW, Rabbit, Nissan Versa, Chevrolet Aveo, etc. come in hatchback form.

- 18-25 year-olds are much more open to a hatchback configuration, and in fact, many in this age group find the fact that it is different-looking than the majority of other vehicles on the road in the U.S. somewhat appealing.

- Older people and empty-nesters are downsizing and don’t want a crossover-sized vehicle but still want the utility and thriftiness of a small hatchback.

- It is believed that a growing percentage of all drivers will become more interested in a hatchback bodystyle over the next decade as they realize the hatchback vehicles offer the same quality and amenities as other bodysyles, in addition to added utility.

Ford stated that production of both the hatchback and the sedan versions of the Fiesta will begin at Ford’s Cuautitlan, Mexico, plant starting in early 2010. Ford announced earlier this morning that they’re going to pour $3 billion USD into Mexico over the next few years, and the Fiesta production is part of that investment.

There is a bit of mystery regarding just which hatchback will be sold in North America, though. According to the Automotive News article:

It’s not clear whether the hatchback Fiesta will be a three-door, five-door or come in both configurations. Ford officials in Dearborn would not confirm the number of doors today. However, Herman Morfin, a Ford spokesman at the plant, said both hatchbacks would be offered alongside the sedan in the United States. He later modified his comment to say Ford hasn’t determined which version of the hatchback will be sent to the U.S.

Ford CEO Alan Mulally, in a press conference, said the automaker hasn’t decided which configuration will be used. “Ford is absolutely committed to leveraging our global assets to accelerate the shift to more fuel-efficient small cars and powertrain technologies that people really want and value,” Mulally said in a statement.

I guarantee he means every one of those words. The shift to small cars in the U.S. completely wrecked Ford’s plan for returning to profitability, and they want to get back on track as soon as possible, and they need more small cars to sell in order to do that.

Ford released the following PR photos of the Fiesta to all the media publications today; we have posted them here so you can see the difference between the 3DR and the 5DR bodystyles.


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Editorials, Features

Ford "Flexes" The Truth In Releases About New Crossover

4 Comments 30 May 2008

By Kevin Miller

05.30.2008

Ford issued a press release earlier this week whose title in the email string screams “FORD FLEX’S DESIGN HELPS CUT DRY CLEANING BILLS”. The release declares that the new Flex crossover is “the world’s first trouser- and dress-friendly vehicle.” They even provided photos of peoples’ clean legs stepping in to a dirty Flex.

The press release goes on to describe that the Flex team engineered a concealed rocker panel into the new vehicle. Ford designers stretched the width of the Flex to wrap around the sill, bringing the step-in area inboard for much easier access by passengers. In combination with the hidden rocker, the Flex door was designed to wrap under the sill, effectively sealing out the elements. With some dry cleaners charging as much as $10 to launder a pair of slacks, the practical Flex design has an immediate and tangible benefit. Really, the Ford press release discusses dry cleaning prices. And now I am.

“The clever design minimizes your clothes’ exposure to the elements. There’s no sill area where dirt usually collects.” said Rich Gresens, Flex chief designer. “We approached the Flex design with one idea in mind: create a vehicle that appeals to customers wanting an exciting alternative people mover. Hidden rockers, refrigerators and tailored leather interiors are just a few examples of how we deliver.”

Such a design is quite clever indeed. And perhaps it is an industry first for crossover vehicles, or even for domestic vehicles of any kind. But “world’s first” is simply untrue, and is where Ford has crossed the line of fact in touting its crossover.

I don’t know what the world’s first vehicle with protected rockers was. But I know that one such vehicle is parked in my garage, and it was introduced almost three decades ago. The original Saab 900, manufactured between 1979 and 1994, has rocker panels which are concealed by the door, a feature which was pointed out in the car’s sales brochures. It was one of the many unique features of Saab’s long-serving first-generation 900 when it was introduced. It really does keep pant legs from getting dirty. It’s a great idea.

So while Ford may feel their boxy Flex is the best, most innovative and stylish vehicle ever introduced, they ought to check their facts before claiming a “world’s first” design feature. And then they should show some respect to the Saab 900.

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News

Toyota May Make Prius in California

5 Comments 30 May 2008

Will there be a General Motors version of the car?


By Brendan Moore

05.30.2008

The news out of Tokyo this morning says that Toyota is considering building the hot-selling Prius hybrid at their Fremont, California plant.

Toyota has shared the plant, called NUMMI (New United Motor Manufacturing Inc.), with General Motors since 1984. The production facility currently makes Toyota Corolla, Toyota Tacoma, and Pontiac Vibe vehicles.

The story was first reported by Tokyo Shimbun, one of Japan’s major daily newspapers. Tokyo Shimbun did not name any sources for their information, an unusual occurrence if a Japanese newspaper feels confident about their story.

If true, the news is noteworthy, for two reasons. The first reason is that it will be the first time the Prius will be produced in the U.S. The Prius is currently manufactured only in Japan and China.

The second reason is that it really begs the question of whether General Motors, with Toyota’s blessing, would be able to leverage the Prius production in the plant to make their own version of the Prius. If so, would General Motors even be interested in producing such a vehicle, considering the plug-in hybrid Volt is on the way and General Motors already has a two-mode hybrid engine in production? Of course, with SUV and pickup sales plummeting, GM may decide that it might not be a bad idea to have another hybrid car for GM shoppers to buy. Lots of ifs and maybes in that particular scenario. But, if Toyota does want GM to make their own version of the Prius (amortize those costs, boys), and GM wants to do that, it’s not as if that decision is laden with risk on GM’s part. Toyota has sold over a million units of the Prius since it was introduced in 1997, so it has been established that consumers like the car.

Of course, Toyota refused any comment on the news article: “As usual, we don’t comment on the details of negotiations, but nothing has been decided yet on the reported NUMMI case.”

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Features, News

Credit Crunch Hits US and European Subprime Auto Buyers

2 Comments 30 May 2008

By Kevin Miller

05.30.2008

Subprime auto buyers on both sides of the Atlantic are having increasing difficulty finding vehicle financing. This credit crunch is an indirect result of the subprime mortgage crisis, as lenders are looking much more closely at the qualifications of prospective borrowers, leaving bottom-tier borrowers without financing.

Auto lenders, just like lenders in other sectors, are having a more difficult time to obtain money for loans, and the money they do find comes with higher interest rates. Because the amount of money available to loan has dried up, auto lenders have had to cut back on making new loans. In the past six months, most auto finance companies have increased requirements for borrowers. Among those more stringent loan requirements are mandatory higher down payments, higher monthly payments, and higher credit scores.

Because of the shortage and expense of money to loan, lenders in the US and the UK are not willing to make loans to buyers with poor credit history. Many lenders are scaling back or eliminating loan programs which cater to car buyers with subprime credit. This fact is likely to affect new vehicle sales, as buyers who cannot get financing for a new vehicle are forced to choose older, less-expensive used vehicles.

In recent years when lending standards were less stringent, many vehicle buyers relied on home equity loans to finance vehicle purchases. Devaluation of properties, combined with tightening of lending standards, has eliminated that source of financing for many would-be auto buyers.

The current economic slowdown in the US has resulted in an increased number of vehicle repossessions, as consumers are unable to make their vehicle payments. The large number of repossessions, in addition to the more-stringent lending standards and slowdown in new vehicle sales, has put pressure on the used-car market. In April, sale prices dropped 5.9 percent from a year earlier, with trucks and SUVs falling even more, according to the Manheim Used Vehicle Value index. Prices had been rising for more than four years until last fall. Lower used car values hurt financial groups who handle vehicle leases, as vehicles coming off lease are worth less than their projected residual value at the end of their lease, sometimes costing the lender several thousand dollars (in loss) per vehicle.

The 2008 new vehicle sales forecast for the US predicts sales of around 15 million vehicles this year, which is significantly down from the 16.2 million new vehicles sold in 2007. If that prediction comes true, this will be the slowest year for vehicle sales since 1995. Such a dramatic sales slowdown will have a slowing effect on the overall US economy, as hard times in the auto industry ripple through many sectors of the economy.

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News

GM to Debut HCCI Sparkless Technology on Opel Insignia

4 Comments 29 May 2008

By Chris Haak

05.29.2008


According to Motor Authority, GM’s new Opel Insignia (which is its replacement for the Vectra, and will also become the next Saturn Aura in the US) will be the first GM vehicle to feature HCCI sparkless ignition technology. It is not clear if the next Saturn Aura will also feature the HCCI technology at its launch.

HCCI, which stands for homogenous charge compression ignition, gives gasoline engines a 15% efficiency boost compared to a conventional engine with spark plug ignition. Due to the technology’s infancy and some limitations that have not been overcome, the HCCI ignition will only work from idle speeds up to about 55 miles per hour; beyond 55 or under increased load/power situations, conventional spark ignition would be employed to power the vehicle.

HCCI is basically a combination of gasoline and diesel engine technology; diesel engines also combust their fuel via compression ignition and not a spark plug. However, HCCI has the advantage of using gasoline instead of diesel fuel, and also the ability to combine the best traits of both gasoline engines (higher-RPM power, smoother and quieter operation, cleaner emissions) and diesel engines (low-end torque, fuel economy).

GM isn’t the only manufacturer developing HCCI technology; Mercedes-Benz has shown its so-called DiesOtto technology (which is basically the same idea) at some auto shows. In demonstrations, a DiesOtto-powered S-class sedan achieved 39 miles per gallon. Volvo and Volkswagen are also investigating HCCI technology.

To get an idea of how compression ignition works, think back a few decades before sophisticated electronic fuel system controls were widespread in automobiles. Have you ever heard a car engine that had just been turned off “dieseling” – basically, continuing to run, albeit roughly, on its own? That’s compression ignition.

The challenges for engineers include developing sophisticated engine control computers to effectively harness the process, as well as improving upon its refinement.

Personally, I’m excited to see developments such as HCCI on the immediate horizon. When combined with other fuel-saving technologies (forced induction, direct injection, six-speed transmission, and more), perhaps there is hope that we won’t all have to drive subcompact cars to either meet increasingly strict fuel economy standards, and might still be able to afford to fill our gas tanks ten years from now.

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Features

Focusing in Croatia

2 Comments 29 May 2008

Two countries, gorgeous coastlines, and 12 hours to do it


By Blake Muntzinger

05.29.2008

Road map? Check. Bags? In the trunk. International Driver’s Permit and passports? Yep. Paper with random Croatian phrases? Got it. Everything was in place for the last great European road trip – this time in Croatia. Everything, that is, except sunshine. But that didn’t matter. Sun isn’t required to enjoy the Dalmatian Coast. Destination: Dubrovnik.

Two days earlier, after my friend and I decided the possibility of bearing another dizzying bus ride was nil, we opted to share the cost on an Avis car rental. Our desired Class A (Toyota Aygo size) was unavailable, so our upgrade to a silver 2007 Ford Focus five-door was a pleasant surprise. Its mere 1,496 kilometers (930 miles) on the odometer at pick-up was also surprising, especially for a rental car.

We set off from Split at 8:30 am, committed to return the Focus with a full tank of gasoline to the Dubrovnik office in 12 hours. And so the journey began. Our highway of choice was a two-lane road called the D8. This direct route connecting Split and Dubrovnik assured us that getting lost was impossible since it snaked along Croatia’s awe-inducing coastline.

Ten minutes into the drive, while wallowing in self-praise for bypassing much of the morning rush, I encountered a should-have-studied-the-controls-before-driving moment. I fiddled with the rear wiper switch in a futile attempt to clean the rear window. However, in doing so, I didn’t realize what I did to activate it, so I couldn’t turn it off. Not wanting to pull over for something that, we continued along with the rear wiper on a delay, yet cleaning nothing. Only a few minutes later after squirting washer fluid on both sets of windows, operating both sets of wipers, and searching through the Croatian-written owner’s manual did we discover a simple tug on the stock would have solved the problem. That’s what I got for just looking at the symbols – not exactly my smartest moment.

Trekking through the breathtaking mountains and handling the curves was a breeze in the Focus. Its quiet 1.6 liter, Zetec four-cylinder engine was mated with a stiff suspension to deliver the proper combination of power and control. I never felt I couldn’t handle the car on the road’s steep inclines and curves. Nothing sporty, but the ride was satisfyingly smooth. Brakes were strong and solidly slowed the car without concern. Croatian driving isn’t for the easily excitable, not because of road quality or knowing the traffic laws, but because of the speeding motorists overtaking multiple vehicles without caution on curvy roads. Unobstructed rear visibility allowed me to anticipate these cars, while the brakes came in handy when oncoming traffic caused said drivers to cut into our lane.


The Focus’s interior quality, even before the restyle, made me envious of our European counterparts. It might not be marketed as a classy car, but all things being equal, it’s a cut above. Even though our rental was a lower trim level, with crank rear windows and cloth seats, it felt more substantial than that. Ford’s attention to detail seems more evident here; it’s remarkable what some properly placed chrome and aluminum-colored accents do to an interior. The dash was straightforward with easy-to-reach quality HVAC and radio dials that have only improved in look and feel for the 2008 model. Easy-to-use and convenient cruise control and radio/CD functions were mounted on the steering wheel.

Studying this model’s lines got me thinking about how it compares to the Focus west of the Atlantic. The second-generation Euro Focus was penned with lines to age gracefully. It still looks good parked next to the 2008 model, thanks to its sleek, simple shape. It will likely still look stylish in five years. For North America, while all versions are based on the original platform to a degree, the 2005-2007 model is arguably better looking than the 2008. The ’08’s front fascia is flashy and edgy but doesn’t flow like the previous version. It’s different and hides the wrinkles, but it tries too hard. The platform is partially to blame; however, perhaps Ford went slightly overboard.

Four and a half hours into our adventure, after stopping to admire the views, detouring into the mountains, and crossing through Bosnia-Herzegovina, we reached Dubrovnik. After nixing the idea to head to Montenegro due to time concerns, our mission was to locate our accommodation and return the car.

Dubrovnik’s main thoroughfares are generally well marked and wide enough for easy travel in either direction. Getting off those streets nearly spelled disaster for our car and trip when we discovered our temporary abode was on a street wide enough for two vehicles when nothing was parked. Even with vehicles on the sidewalks, I felt a tinge of panic downshifting up hills, protecting the side mirrors, and turning around. It had me questioning my sanity and thankful we weren’t upgraded to anything larger.

When all was said and done, we burned just under a quarter of a tank of unleaded Eurosuper 95 octane gasoline, which was about $28. Having driven the 2007 Focus in Croatia and seen the 2008 model in Geneva, I’m looking forward to the next-generation world Focus at the end of the decade. If the new Fiesta and promises of synergy between the two Fords are any indication, Ford will have no problem selling them, and might possibly make buyers forget about a certain second-generation blunder.


Even if the sun wasn’t out all day, our little Croatia voyage was still a memorable once-in-a-lifetime experience. If I make it back, I’ll be sure to continue on the D8 to Montenegro to check out the landscape. Maybe I could get the Focus RS.

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News

Fiat Considering Selling the 500 in the US

5 Comments 29 May 2008

By Chris Haak

05.29.2008

According to Automotive News, at the Automotive News Europe Congress in Turin last week, Fiat Group Sergio Marchionne said that his company is considering selling its iconic and wildly popular 500 minicar in the US. Further, the company wouldn’t do so unless it actually built the car in the US, as importing a small, premium car from Europe would be extremely cost-prohibitive with the current weak dollar situation.

When Alfa Romeo, which is also owned by Fiat Group, finds a plant to build its vehicles to springboard its US relaunch in late 2009, that same facility could also produce the 500. By the company’s own admission, they are speaking with anyone and everyone in North America about a potential production agreement; obviously, there is a lot of unused production capacity in the US right now, but some of the most flexible plants are the newer ones that haven’t been mothballed. It sure would be neat to see an old Big Three facility get a new lease on life building Italian cars, though.

Fiat has seemingly mimicked key parts of the brand extension strategy of BMW’s Mini brand with the 500; the three-door hatchback arrived first, in 2007. It will be followed by a convertible in 2009, then a long-wheelbase version in 2010 (that sounds very much the equivalent to the Mini Clubman from reading a description of it). Lastly, and again from the Mini playbook, Fiat is considering an SUV-like derivative that might include all wheel drive.

Assuming that the 500 can make the trans-Atlantic journey relatively unscathed (without being de-contented or diluted), it would be an instantly credible premium small car entry for a country that suddenly has found an appetite for them. Interestingly, Marchionne said that if Fiat does sell the 500 in the US (which at this point sounds pretty likely if the CEO is chatting about it with reporters), it would not mean that the Fiat brand will return to the United States. Mr. Marchionne, probably correctly, considers the 500 to be a brand by itself. With an expanded lineup of 500s, it would have the same number of models that Mini is likely to have.

An unanswered – and possibly un-asked – question is where the 500 will be sold. There are not US Fiat dealers; the company is going to re-launch Alfa Romeo with a six-figure flagship at select Maserati outlets (Maserati is also under the Fiat umbrella), and eventually there will be Alfa Romeo dealerships when the more pedestrian models are produced and sold in the US. I suppose that the 500 could be sold at the Alfa Romeo stores when they come online.

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Features

Ultimate Defender Blings Up Land Rover’s Old Warrior

2 Comments 28 May 2008

By Andy Bannister

05.28.2008

It takes a special vehicle to achieve the distinction of looking as effortlessly at home in every situation on and off-road as Land Rover’s evergreen workhorse, the Defender.

The Defender may be absent from North America these days but it is still available in a large number of markets around the world, selling a steady 25,000 or so annually in a style which has hardly changed in 60 years.

In Britain they are used by everyone from the army, police and coastguard to farmers across great swathes of this green and pleasant land. Her Majesty The Queen has been known to drive one around her Scottish estate, and trendy city types love them.

In a country where SUVs are fast becoming public enemy number one, the Defender somehow seems exempt, even cultivating a “green” image as the chosen mode of transport for conservationists.

To celebrate Land Rover’s 60th year of existence, small numbers of what is dubbed the ultimate Defender – the SVX, carrying more than its fair share of designer “bling” – are now trickling on to the market at a cost in excess of £30,000 (almost $60,000).

The original Land Rover made its debut at the Amsterdam Motor Show in 1948, and was intended to be in many ways a stopgap for the Rover company, which can hardly have dreamed what success lay ahead. Rover was at that time struggling with its middle class saloons in the austere world of post-war Britain, where there wasn’t enough steel to go round to make all the cars buyers craved.

The Defender shares plenty of DNA with that pioneering model, although the current Defender design (if not the name, which came later) was actually launched back in 1983 by then-owner British Leyland. Stylistically, it was hardly changed from the original. By that time the little Land Rover was a national institution, having seen off its one-time home-grown rival, the similar-looking but much-less-successful Austin Gipsy.

Despite growing slightly more sophisticated over the years, the Defender has always been a pretty slow, uncomfortable vehicle to drive on tarmac, though you would never think so judging from its popularity with buyers who rarely use its off-road capabilities. Its driving position is less than ideal and the interior has always been spartan, although a 2007 facelift certainly moved it forward in leaps and bounds.

The special SVX model comes only with metallic black paint and grey decals, which sit slightly uncomfortably with the utilitarian appeal of the design. It possibly runs the risk of appearing a little bit too customised for a venerable old vehicle – particularly the grille and roll cage – although Land Rover is hardly likely to struggle to sell the few hundred it is producing.

In the UK the SVX is based on the short Defender 90 (it has a 90-inch wheelbase), available as both a station wagon and – for the first time in the UK for many years – a soft top. Perhaps disappointingly the SVX shares its mechanical layout with the standard Defender, including the recently revised 2.4 litre four-cylinder Ford turbodiesel engine, although better damping means a smoother ride.

Equipment includes Recaro seats, alloy wheels and distinctive bright work, including a silver coloured grille and headlamp surround. There’s also an iPod connection, uprated sound system and sat nav.

Some owners will never find out but the Defender performs as brilliantly off-road as it has always done, thanks to great ground clearance, excellent axle articulation, a locking centre diff and clever traction control.

Interestingly, Australians also have the chance to buy (in tiny numbers) their own version of the SVX, but this time based on the longer-wheelbase 110 station wagon with five doors and seven seats

Whilst the Defender is not the world beater it once was – Japanese models like the Toyota Land Cruiser muscled it out of the way years ago in many markets – the SVX undoubtedly has a certain presence, though personally a standard model in a time-honoured shade of olive green would be more to my liking.

One of the problems Tata – Land Rover’s new owner – will be wrestling with is what form the promised 2012 Defender replacement should take. The design is increasingly out of step with modern legislation and simply can’t go on for ever.

Still, sales are up on recent years and the Defender seems to be enjoying a golden autumn. Whilst an anniversary special is well and good, let’s hope they don’t do TOO many tricked-up special editions. The old warrior deserves a dignified last few years.

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Editorials, Features

Carbon Fiber for the Common Man

3 Comments 28 May 2008

Or, if we make it cheaper and greener we could probably sell more of it

by David Surace

05.28.2008

Paul Tan, the highly-informed automotive blogger and industry hawk from Malaysia, has given me another pink highlighter moment regarding carbon fiber’s place in our energy-conscious age:

“A group of Japanese companies which control 70% of the global carbon fiber market want to increase the usage of carbon fiber in automobiles.”

Goshers, really?

You see, carbon fiber–or if we’re picking nits, carbon-fiber-reinforced-plastic, a material with the strength of steel at only 1/3 the weight–is certainly no stranger to the automobile, as our man Bruce McCulloch covered around this time last year. But right now the lion’s share of the material still goes to large aircraft manufacture, specifically airliners, where the fuel savings more than make up for carbon fiber’s stratospheric cost and slow manufacturing time.

In an automobile, which is several orders of magnitude smaller, less expensive and quicker to build, the return-on-investment argument for carbon fiber is harder for the average consumer to swallow. So for right now, it’s still the preserve of supercars, F1 paddocks and high-performance toilet seats.

But what if it wasn’t? What if it became the ho-hum everyday composite for everyone? And what would replace it?


Let’s address the first question: according to the interesting Automotive News article (subscription req’d) which Mr. Tan sources, the big carbon fiber manufacturers in Japan, Toray Industries, Teijin and Mitsubishi Rayon, have plans up their sleeves to increase production of the material and, in turn, cut the exorbitant cost to the consumer. And, in turn, make gobs of money.

Now, for those of you who only have vague ideas about what carbon fiber is, I invite you to think of it like reinforced concrete. The tiny carbon strands (about 6 micrometers thick) are woven together in a matrix similar to the steel rebar used to erect your local Wal Mart. Those strands serve to spread weight or force across the entire body of the structure, instead of gathering it at a single weak point. Then you can add a liquid element which can harden; in Wal Mart’s case it’s concrete, and in carbon fiber’s case it’s plastic resin or epoxy. Whereas concrete hardens in the sun, the epoxy must be baked in a very hot oven called an autoclave in order to stiffen up.

With the multiple pieces all smooshed together, a lot of people like to call the resulting material a “composite”, kind of like a composition is simply a body of work (like an opera, or a term paper) made of many parts.

If you can imagine every Wal Mart being built out of solid blocks of travertine stone like the Colosseum in Rome, you can see why the steel rebar & concrete combination has been so popular.

But if it’s like rebar then why is it so bloody expensive? For starters there’s the carbon strand itself: you begin the process with individual fibers of a very nice material called Polyacrylonitrile (the “acrylic” content of your t-shirt is made out of this same material), then burn it to within an inch of its life. If you cooked it right, the end result is about 55% pure carbon, and those carbon atoms excitedly arrange themselves into a very efficient hexagonal pattern called a graphene sheet. In tubular form, this is now your carbon strand, anxiously waiting to be made into a toilet seat.

One of the really neat things about this material is that, depending on how you weave the carbon fibers, the composite material can either bear loads in all directions (omni-directional), or it can hold up against stress coming from only one direction. Formula One teams often use the “uni-directional” material to make delicate control arms and suspension pieces, which bear most of their stress in side-to-side or up-and-down motions.

But an F1 car is clearly a cost-no-object application. The challenge for Japan’s automotive carbon-fiber players is to make it a value-added proposition over the already trustworthy steel and aluminum alloys. Fortunately for them, however, your daily driver doesn’t have to endure nearly the amount of stress of an F1 car on day-to-day basis.

So why not make the strands out of a less stringent material for, say, non-structural parts? Scientists are already experimenting with recipes for Short Fiber Reinforced Polymer, a material which uses some “split ends” of acrylonitrile carbon fiber strands, usually blown in at odd angles to create an interlacing effect before the resin material is poured in. This material is not nearly as strong as woven carbon fiber, and would never be mistaken for an “advanced” composite, but with the help of an old friend, glass fiber, you can make what is essentially a re-re-reinforced fiberglass.

What about fibers made of things other than acrylic? For years experiments have been underway to determine a suitable (and petroleum-free) successor to acrylonitrile, one that perhaps might even yield a higher concentration of carbon atoms per strand, from natural fiber extracts like cotton, hemp, sisal and curaua all the way up to metal fibers made of highly-elastic aluminum alloys. The goal is to find a reinforcing material that’s easier, greener, faster and cheaper.

Or how about reinforcing your composites with something that isn’t a fiber at all, but a clay? Great minds in materials engineering have also been plugging away at so-called nanoclay composites, a class of reinforced plastic that uses ultra-fine particles of a natural clay called montmorillonite, a fine, powdery, almost greasy-feeling clay originally discovered in the eastern French town of Montmorillon. Like the graphene sheets that carbon atoms like to form, the alumina and silica molecules in clay minerals also like to form orderly shapes, using their shared oxygen atoms to form corners in a linked tetrahedral shape. These guys then lock together with other clay-making molecules to form rigid sheets.

Sounds far fetched? There’s already a company bringing these things to light: PolyOne Corp., an plastics manufacturer out of Avon Lake, OH is already playing with montmorillonite-infused polymers which are strong enough and stiff enough to stand up on their own as an automotive body application.

Going just a little further, you could imagine an automotive paint process that only involves one or two super-thin layers of nanoclay-reinforced primer and colorant, followed by one single layer of “self-healing” clearcoat. On top of being tougher and reacting to scratches by bursting tiny nanocapsules full of “clearcoat” resin, the weight savings over a traditional automotive paintjob (which typically involves between 4-10 coats) could be significant.

While those things are cooking, however, carbon fiber’s meticulous manufacturing process should become faster, easier, and more open-source (as of right now, carbon weave processes are still fiercely kept a trade secret). So perhaps by the time my (unborn) children are in the market for a minivan, the once-exotic carbon weave will have gone out of style–and come back again.

Postscript: If you’re still thirsty for more information about Fiber-Reinforced Composites, there’s a very good synopsis from the Engineering Fundamentals website available HERE.

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Reviews

2008 Toyota Sequoia SR5 4×4 Review

5 Comments 28 May 2008

By Chris Haak

05.28.2008

Although full-size, body-on-frame SUVs are a rapidly declining segment of the new vehicle market, thanks to the reality of gas prices that have more than doubled since 2005 and are showing no signs of falling, they are still members of a very large segment. There are many people who need the utility, towing capability, and passenger capacity of the Suburban/Yukon/Tahoe/Escalade, Expedition/Navigator, Armada, and Sequoia, although their segment of the market will never sell as many vehicles in future years as it did in the past 5-10 years until Katrina started the gas price march to $4.00 per gallon and beyond.

This brings me to my most recent test vehicle, a Toyota Sequoia SR5 4×4. Although I don’t have a large family, or any current towing needs, I feel that I am uniquely qualified to comment on the vehicle, as I have driven versions of three-fourths of its closest competitors (missing only the Ford products), including thousands of miles of seat time in a 2007 Chevy Suburban and a test drive in a 2008 Infiniti QX56. I’ve also spent time in several crossovers – a growing segment that is gobbling up market share from their larger, heavier, thirstier brothers – including the Buick Enclave – as well as several minivans. Finally, my family and I own Toyota’s own Sienna minivan. More on that comparison to come later.

The Sequoia is in its second generation and is based on the Tundra pickup (which is also in its second generation). As the Tundra grew from a 7/8ths-scale version of a domestic pickup into a full-scale version, the Sequoia did as well, which substantially improved interior space and performance, with no fuel economy penalty compared to the previous generation. The thing is huge, and can be intimidating in smaller garages (or public parking garages) where tight maneuvering and acute awareness of your vehicle’s width and height are critical.

Exterior
The outside of the Sequoia basically looks like the SUV version of the Tundra pickup that it effectively is. The grille and front bumper are different between the Sequoia and Tundra (with the Sequoia having a fully body-colored bumper, while some trim levels of the Tundra favor a chrome treatment on the bumper’s lower half), and the Sequoia lacking the Tundra’s phony vent at the top of the grille’s arch. I prefer the Sequoia’s cleaner look, but they’re so similar that I had to compare photos to tell the difference, other than noticing that the fake vent was missing in the top of the Sequoia’s grille.

My test vehicle was an SR5 4×4 model, which is below the Limited and Platinum models in the trim line hierarchy. Externally, there aren’t many improvements in the higher-end models aside from larger wheels, but my test vehicle’s dark blue exterior, with no adornments such as moldings or chrome strips, and 18 inch wheels (when the Platinum trim, as well as many competitors, has 20 inch wheels) seemed a little ho-hum. I’m all for good taste and a certain amount of restraint when it comes to vehicle styling, but the Sequoia’s flanks are showing almost too much restraint. At least the Sequoia has deep-cut character lines on the lower portions of the doors, and the swept-back headlights and taillights lend a fairly modern look. Like the Tundra pickup, the Sequoia isn’t quite as conservatively styled as its competition, although I’d argue that the Suburban’s clean lines are more handsome.

Interior
The new 2008 Sequoia grew in nearly every dimension compared to the previous model. Although it’s a very large vehicle and Toyota’s engineers could have easily been tempted to “waste” interior space because there was so much to go around, they wisely applied many of the clever space maximization techniques that would have been applied to a smaller vehicle. For instance, thanks to independent rear suspension, the third row seats fold flat into the floor as their competitors (except for the GM trucks) do. Multiple clever storage cubbies abound, including dual glove boxes, a gigantic center console that has the ability to hold hanging files, and – if my count is correct – 17 cupholders for 8 seating positions. Further enhancing interior flexibility is the fact that the second row seats each slide forward or backward individually on tracks, so for owners who plan to use all of the seating positions (or at least all of the rows), the vehicle’s available legroom can be allocated according to the needs of occupants in each row. For example, if the front seats are all the way back, the second row might have to be adjusted rearward a bit more than normal for occupants there. I appreciated that the Sequoia gave that flexibility.

It was also very easy to get into the third row; I remember growing up in the 1980s, my parents owned several Suburbans of the 1973-1991 era; to get into the third row (which didn’t even have any footwell), your choices were to climb over the second row without folding it (OK for kids, but parents didn’t like it), or fold the seat forward and the seatback flat. The Sequoia (as well as its contemporaries) have a much simpler method – just pull one lever on the side of the second row seat, and the bottom portion of the seat slides forward and the seatback leans forward, leaving a large opening which, combined with long rear doors, makes it pretty easy to enter the third row gracefully. Exiting gracefully, however, is more difficult. Your two choices are to face forward and limbo under the top of the door opening, or face backward and blindly hoping that your foot will hit something solid like a running board before your knee or shin hits the bottom of the door opening.

In terms of interior materials, I was frankly disappointed. There are very few, if any, soft-touch plastics. The entire upper dashboard was made of hard plastic, and the majority of the door panels and other touchpoints were as well. I was also unpleasantly surprised by the deletion of content in the SR5 relative to the Limited and Platinum models. For example, the SR5 had cloth seats, non-lighted visor mirrors, no retractable sun shades, no power liftgate, and a vinyl steering wheel (no leather wrap – which is included on the $18,000 Corolla I’m driving today).

Driving Experience
Obviously, the Sequoia is not a small, light vehicle. Expect to have to forego shorter or narrower parking spots at the mall. Forget about jumping into any small gaps in city traffic. However, once you get used to the size (which only took me a day or two), it really drives almost like a smaller vehicle, which is a complement to Toyota’s chassis engineers. Other than the unavoidable step up into the front seat and the Grand Canyon-wide space between the front seats, it’s almost possible to forget that you’re in a three ton truck. The Sequoia is solid over uneven road surfaces and, thanks to independent rear suspension, felt almost car-like in its highway ride. The big guy doesn’t particularly care for traveling quickly on back roads, but didn’t feel unsafe or top-heavy at any point, so long as things were kept at a reasonable pace.

I’ve gushed before about the 5.7 liter V8/six speed automatic combination in my review of a 2007 Tundra CrewMax, and all of that feedback still stands for the Sequoia. Acceleration and braking performance felt remarkably similar, which is not surprising, considering that the Sequoia SR5 4×4′s curb weight is only about 5% (or 300 pounds) heavier than the Tundra CrewMax 4×4′s. The six speed automatic was always in the right ratio for the situation at hand, and it shifted too slowly when in manual mode. That really didn’t matter, though, because 381 horsepower and 401 lb-ft of torque is enough to overcome any situations where the transmission might be a gear or two higher than you’d want it in.

Steering feel was actually fairly accurate for a large truck. Since it’s a traditional belt-driven setup instead of the electrically-operated units finding their way into smaller vehicles, it actually managed to feel better to me than several small cars I’ve driven. Navigating through the multi-story parking garage I use daily wasn’t as difficult as I thought it would be – I just had to have confidence in my feel for the Sequoia’s size when rounding sharp corners and aim the steering wheel. It (and I as its driver) survived a six-story descent from the top floor to the exit one busy afternoon, which meant twelve sharp right turns that required me to turn the wheel to a point near its lock; the only oddity was when there was a midsize sedan in front of me on a descending ramp, and I literally could not see the roof of the car over the Sequoia’s hood, because it was below my level and the hood was so high. Luckily for me (and the driver of that car), I was aware that he was there and of course didn’t bump him.

The enormous width of the Sequoia presents its own set of challenges; for instance, aside from having to look for wider parking spaces, putting it into a garage, or even patronizing some drive-through windows, sometimes requires folding the driver’s mirror. The SR5 was not equipped with power folding mirrors, so I had to reach out to do that by hand. In spite of the wide mirrors, I managed to avoid whacking any objects with them. I attribute that again to respecting the size of the truck and being vigilantly aware of its width at all times.

As I do not own a boat, car trailer, horse trailer, or travel trailer, I was unable to test the Sequoia’s towing capabilities. However, the maximum trailer weight for a Sequoia SR5 4×4 is 9,600 pounds (an even 10,000 for an SR5 4×2), which is a heck of a large trailer. I have no doubt that it would do a great job towing, with the combination of an intelligent transmission (with tow/haul mode), strong engine, and hefty curb weight (for stability).

Fuel Economy
Today’s astronomical fuel prices have already winnowed the pretenders from the people who genuinely need a vehicle this large and capable. To that point, nobody buying a Sequoia does so for fuel economy reasons; however, its figures are class-competitive. The 5.7 liter V8/six-speed automatic combination is rated at 13 city/18highway for the 4×4 models and 14/19 for 4×2 models. These figures are slightly worse than the Tahoe’s 14/19 for 4×4 models and 14/20 for 4×2 models with the less-powerful 5.3 liter engine, but better than the AWD GMC Yukon Denali’s 12/18 with its comparably powerful engine and six speed automatic. The Ford Expedition’s fuel economy is also in this neighborhood. The Nissan Armada 4×4 is rated at a class-worst 12 city/17 highway. In about 250 miles of mixed driving, including some heavy traffic, I got 13.5 miles per gallon, which is actually better than I was able to achieve in the Tundra with the same powertrain back in February. Perhaps I was getting more used to the V8′s power and was able to keep my right foot out of the accelerator a little more.

Pricing
While I actually didn’t mind living with the Sequoia for a week, it certainly wasn’t the ideal family vehicle for two adults and two small children. (A friend of a friend in the same situation as us has a new Suburban to haul their two children under age two in, and no, they don’t tow anything). I can appreciate the vehicle’s capabilities, and it’s probably where you’d want to be if you knew you were going to collide with another vehicle, thanks to its considerable mass.

I’m not here to convince people to buy a minivan over a Sequoia, but just look at these specs for a moment. Comparing every interior dimension (leg/hip/shoulder room in all three rows, plus cargo volume behind each row) between the Sienna and Sequoia shows the Sienna winning the comparison in nearly every category. The only “wins” for the Sequoia were the width-dependent categories (hip room and shoulder room) in all three rows. However, the Sienna soundly trounces its cousin in terms of cargo volume: 43.6 versus 18.9 cubic feet behind the third row, 94.5 versus 66.6 cubic feet behind the second row, and 148.9 versus 120.8 cubic feet with both second and third row seats folded or removed. On top of that, the Sienna’s curb weight is about 1,500 pounds lighter, so its fuel economy is 16/21 in the AWD and 17/23 in the FWD model. Lastly, According to TrueDelta, a Sienna Limited AWD is over $12,000 cheaper than a Sequoia Platinum 4×4 when equipment differences are taken into account. In fact, you can buy a fully-loaded Sienna with EVERYTHING for the same price as a relatively stripped Sequoia. I’d argue that in today’s environmentally-conscious times, the “minivan stigma” is now less powerful than the “eww, you drive a full-size SUV” stigma. I’m not judging those who choose the big SUV over the van, but economically, it doesn’t make much sense unless you need its capabilities. I’d like to re-iterate that I am not advocating the elimination of full-size SUVs from the marketplace or saying that people should not be allowed to buy them. I just don’t see why people would.

Conclusion
If you need or want the size, safety, and capability of a full-size body on frame SUV, the Sequoia is a very credible effort from Toyota. I feel that the interior materials and design are a bit of a letdown asethetically, but the powertrain was awesome (if a bit thirsty), engine performance was superior, and the interior had a lot of clever storage cubbies. Meanwhile, if anyone would like to loan a large boat to me for a weekend to test the towing capabilities of the next large vehicle in my garage, please let me know.

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