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2019 GMC Sierra carbon fiber bed: How it's made

FORT WAYNE, Ind. — The redesigned 2019 GMC Sierra has some pretty nifty features, and the one that has had the most attention is the MultiPro flipping and folding tailgate. But the Sierra also features the first-of-its-kind carbon fiber truck bed. It's interesting, of course, for its capabilities, such as being 62 pounds lighter than the all-steel box. It even adds more cargo volume since the material can be assembled and shaped differently from steel. As it turns out, the assembly process is cool, too, which we learned when GMC invited us to see the beds being made. Every GMC carbon fiber bed starts out as perfectly flat sheets of thermoplastic carbon fiber. The sheets consist of a mix of fibers and resins, a bit like the molded carbon fiber parts Lamborghini uses. The sheets are manufactured by Japanese company Teijin, which collaborated with GMC to develop the bed. They're all delivered to Continental Structural Plastics (CSP) in Fort Wayne, Ind., for construction into the actual bed. The company, a subsidiary of Teijin, makes a wide variety of composite and plastic parts for the car industry, including body panels for the C7 Chevy Corvette. The rectangular sheets are cut to shape and stacked up at a giant stamping press. Robots pick up sheets and slide them onto a conveyor that goes into a large oven. The heat softens the parts so they can be stamped. The large primary bed parts such as the base are stamped by CSP's enormous 3,600-ton press, and the smaller ones go through a 1,000-ton press. Each press can do different parts using different stamping dies, and CSP switches between dies to produce different batches of parts. After stamping, the parts roll out mostly ready for assembly, but there are rough edges that are trimmed off by water-jet cutters. These cutting machines also create holes for fasteners and for parts such as tie-down hooks and lights. The stamping process also provides the carbon fiber bed with a unique Easter egg. On the bottom of the base of the bed, there are two words: "Connors Way." This is a tribute to Tim Connors, who was the chief engineer of manufacturing at GM and a strong proponent of the carbon fiber bed. He was tragically killed in a motorcycle crash a few years ago. The words were added to honor him, and they were fortunately approved for production. There are some components to the bed that aren't stamped from the flat sheets of material.

Two More Recalls Push GM Total To 4.8 Million In A Month

General Motors announced two more recalls late Friday, bringing to 4.8 million the number of cars, trucks and SUVs the automaker has called back for repairs in the past month. The string of recalls, topped by an ignition switch problem in compact cars now linked to 13 crash deaths, has embarrassed the company and sidetracked its new CEO, who started work just over two months ago. GM has admitted knowing about the switch problem a decade ago, yet it didn't recall any cars until February. The recall delay has brought two congressional investigations and probes by the Justice Department and the National Highway Traffic Safety Administration. Late Friday night, GM announced it would recall 490,000 late-model pickup trucks and SUVs because transmission oil cooling lines weren't secured properly in their fittings. Transmission oil can leak from a fitting and hit hot surfaces, causing fires, the company said in a statement. GM said it knows of three fires and no injuries. The recall affects Chevrolet Silverado and GMC Sierra 1500 pickup trucks from the 2014 model year, as well as 2015 Chevrolet Suburban and Tahoe SUVs and the GMC Yukon and Yukon XL SUVs. All have six-speed automatic transmissions. The Silverado is GM's top-selling vehicle and an important profit center for the company. The GMC Sierra also is among GM's top sellers. Dealers will inspect the transmission oil cooling line fittings and make sure they're securely seated, at no cost to owners. Also Friday night, GM announced the recall of 172,000 Chevrolet Cruze compact cars because the right front axle shaft can fracture and separate while being driven. The recall affects cars from the 2013 and 2014 model years equipped with 1.4-liter turbocharged four-cylinder gasoline engines. If a shaft fractures, the wheels would lose power without warning and the cars would coast to a stop. GM says it has warranty reports of several dozen shaft fractures. It is not aware of any crashes or injuries. Dealers will replace the shafts free of charge. The recall allows dealers to resume selling affected Cruzes. GM issued a stop sale order on the cars Thursday night. The recall also covers about 2,500 replacement shafts used to fix manual transmission Cruzes that were recalled last September. In all, GM has recalled 4.8 million vehicles since last month, two million more than the company sold last year in the U.S.

GMC unveiling 2021 Yukon, Yukon XL on January 14

UPDATE: We received a reply back from a representative at GMC confirming that the new Yukon will be revealed on January 14. The text has been updated to reflect this. General Motors is renewing its body-on-frame SUVs, and GMC's Yukon is next in line to receive a full makeover. It's scheduled to break cover on January 14 alongside the long-wheelbase Yukon XL. It's reasonable to assume we would have gotten our first glimpse at the next Yukon during the 2020 Detroit Auto Show had the event not moved to June. The new date is too close to the model's on-sale date, so GMC will unveil it during a standalone event held in Vail, Colorado, according to GM Authority. We reached out to GMC, and a representative confirmed that is indeed the reveal date for the full-size SUV. Spy shots suggest stylists took GMC's two biggest SUVs in a sharper, bolder direction. Both models share the same front end, which borrows styling cues like C-shaped headlights from the Sierra pickup. Brand-specific rear lights help the Yukon models stand out from their Chevrolet-badged siblings, the Tahoe and the Suburban, which hasn't always been the case. The standard Yukon and the Yukon XL will each grow in size, though there's no indication GMC's naming structure will change to reflect that; Yukon XXL admittedly doesn't have much of a ring to it. While we haven't seen the interior yet, we expect it's getting a generous serving of technology, including a new, touchscreen-based infotainment system. The larger exterior dimensions will clear up more space for people and gear, so average-sized adults will be able to fit in the third-row seats. The range-topping Denali variants of both models will return to satisfy those who crave sumptuousness. The sheet metal will hide much of the same hardware found under the Tahoe/Suburban duo, including an independent rear suspension added in the name of comfort and handling. Powertrain specifications should carry over, too, meaning the entry-level engine will be a 5.3-liter V8 rated at 355 horsepower and 383 pound-feet of torque. The list of options will include a 6.2-liter V8 with 420 horsepower on tap, and we're betting the straight-six turbodiesel available on the Bowtie-badged SUVs will also be offered at an extra cost. Rear-wheel drive and a 10-speed automatic transmission will come standard, and buyers will be able to pay extra for four-wheel drive. The next GMC Yukon and Yukon XL will go on sale halfway through 2020 as 2021 models.