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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.

General Motors reportedly considering small electric pickup

General Motors is considering adding a small entry-level model to its range of electric pickups, according to a recent report. The carmaker is currently showing a prototype to a select group of customers to gather feedback about the model before executives decide its fate. Industry trade journal Automotive News claims that it saw the pickup during a workshop organized by General Motors and describes it as being "smaller than the Ford Maverick and the Hyundai Santa Cruz." For context, the Maverick stretches about 200 inches long, 73 inches wide, and 69 inches tall, so it's around 12 inches shorter, 11 inches narrower, and 10 inches lower than the recently-unveiled Chevrolet Colorado. It sounds like this little GM truck would be closer in size to the Brazilian-market Chevy Montana, pictured at top. But unlike the Montana, the model that Automotive News got a look at had two doors, a "low roofline," a four- to four-and-a-half-foot cargo box, and a design described as futuristic and sporty. If launched, the yet-unnamed pickup would be marketed as an "affordable" EV with a base price pegged under $30,000. However, that's a big if: the pickup — whose name hasn't been announced — hasn't been approved for production. "We're creating these to get a reaction and then to try to modify it or move on," Michael Pevovar, the director affordable EV and crossover design for Chevrolet, told the publication. "The input may come back that it's just too small, and that's okay," he added. If it turns out to be too small for buyers, General Motors hasn't ruled out building its entry-level electric pickup on a different architecture to make it a little bigger. It's too early to tell where the electric pickup would slot in the General Motors portfolio if executives approve it. Chevrolet immediately comes to mind, especially considering the sub-$30,000 price point. The model would make more sense with a bowtie on its front end than with a Cadillac emblem, GMC's trucks are normally positioned higher than Chevrolet's, and Buick hasn't built a pickup in many decades. Similarly, there's no word on when it would enter production or where it would be built. With that being said, there's very clearly a market for affordable, small pickup trucks. As of the third quarter of last year, Ford had sold more Mavericks than it had the Expedition or the Ranger. Hyundai hasn't sold as many Santa Cruz trucks, but it's still not too shabby, having beaten out the Venue and Accent last year.

Canada opens probe into 250,000 GM pickups, SUVs over brake performance

Transport Canada, the auto safety regulator, has opened a probe into braking issues in nearly 250,000 General Motors full-size pickups and SUVs after U.S. officials launched a similar probe last year, the agency said on its website. The U.S. National Highway Traffic Safety Administration (NHTSA) in November into 2.73 million U.S. 2014-2016 model year SUVs and pickups after receiving 487 reports of hard brake pedal effort accompanied by extended stopping distance that were attributed to deterioration of the engine-driven brake assist vacuum pump. Transport Canada's probe covers 249,700 2015 through 2017 model year vehicles including the Cadillac Escalade, Chevrolet Suburban, Chevrolet Tahoe and GMC Yukon as well as 2014-2017 Chevrolet Silverado LD and GMC Sierra LD vehicles. The U.S. agency said it had reports of nine incidents of vehicles incurring damage as a result of colliding with another vehicle or fixed object at low speeds and reports of two injuries. NHTSA said if the pump fails to operate, the amount of brake power assist can be significantly reduced, extending vehicle stopping distance. The NHTSA sent GM an information request in a Feb. 7 letter. A GM spokesman said he had no update on the investigation. Reporting by David Shepardson; editing by Jonathan Oatis