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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.

NHTSA upgrades probe into 1.7 million GM vehicles over wiper failures

WASHINGTON — The U.S. National Highway Traffic Safety Administration (NHTSA) said Tuesday it is upgrading an investigation into 1.7 million General Motors vehicles for windshield wiper failures. The auto safety agency opened the probe in November 2018 to see if GM needed to expand a 2016 recall of 2013 model year Chevrolet Equinox and GMC Terrain SUVs to cover additional vehicles. The engineering analysis probe covers 2010-2012 and 2014-2016 Equinox and Terrain vehicles. NHTSA could demand a recall after it completes the probe. NHTSA said it has reviewed 1,900 complaints and reports related to the issue in the 1.7 million vehicles. NHTSA said it has seen elevated failure rates in the 1.7 million vehicles, even though GM said the recalled vehicles have "double the warranty rate and five times the complaint rate." GM said it will "fully cooperate to support their investigation. We do not believe these windshield washer systems are defective." The wiper failures that prompted the 2016 recall were attributed to water and debris intrusion into the windshield wiper assembly ball joints, leading to excessive wear and eventual detachment of the ball joint. GM said it was installing an improved windshield wiper motor and transmission assembly and relocating a drain hole at the base of the windshield. Related Video:

GMC could have used Jeep's prized grille design on its born-again Hummer

General Motors confirmed it's bringing the Hummer nameplate back on an electric, GMC-badged pickup by publishing a dark photo of its front end. The battery-powered drivetrain under the sheetmetal represents a tectonic shift, but we noticed another flagrant break with tradition: it wears six slot-like inserts instead of seven like on every previous Hummer and countless Jeeps. Adding an extra slot wouldn't have landed GMC in hot water. The seven-slot grille has historically been associated with Jeep, and the company proved it's willing to go to significant lengths to ensure another automaker — especially one it perceives as a rival — doesn't use it. Parent company Fiat-Chrysler Automobiles (FCA) bitterly sued Mahindra over the Roxor's design, including its five-slot grille, and won in 2019, forcing the Indian firm to unveil a redesigned side-by-side for the 2020 model year. And yet, stylists would have very likely been able to get away with it on the Hummer. While General Motors owns Hummer, the brand traces its ancestry to 1970, when American Motors Corporation (AMC) purchased Jeep from Kaiser and changed the name of its General Products Division to AM General Corp. The division manufactured the rear-wheel drive, CJ-based DJ for the United States Postal Service and began developing the Humvee in 1979. Jeep and AM General went their separate ways when Renault began investing in AMC. Foreign companies weren't allowed to own defense contractors, and AMC had more to gain by gradually selling out to Renault than by keeping AM General, so it divested the division to LTV Corporation in 1983. Humvee production started shortly after, but no one protested its seven-slot grille because there was no risk of it stealing sales from a comparable Jeep model. It was manufactured exclusively for the U.S. Army, and civilian sales weren't planned. H2SUV View 4 Photos The original civilian Hummer released in 1992 must have raised more than a few eyebrows but, here again, it didn't directly compete with one of Jeep's off-roaders, so no one complained. It was huge, correspondingly expensive, and its portal axles made the YJ-generation Wrangler wet its pants. It's the H2 concept (pictured above) unveiled at the 2000 Detroit Auto Show that set off alarm bells in Auburn Hills. DaimlerChrysler's lawyers counted the slots in the chrome-plated insert that dominated its front end and shuddered when they reached seven.