1969 Volkswagen Westphalia Camper on 2040-cars

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Crash test videos show how rust compromises safety

These recently released Swedish videos serve as a reminder that rust isn't just a cosmetic flaw, when it comes to cars. The insurance company Folksam and the homeowner organization Villaagarnas Riksforbund gathered examples of two relatively popular, but by now rusty cars, and then performed crash tests with them at the Thatcham Research facility in Britain. The results are sobering. The rustier cars chosen for the tests were first-generation Mazda6s, cars that have a reputation for early-onset rust in salty surroundings, such as the Nordic countries in Europe or the Salt Belt in the U.S. The cars in the other end of the spectrum were fifth-generation Volkswagen Golfs, which thanks to their body treatment only really start to show rust at over ten years old. But rust isn't just on the surface, it goes bone deep. While the Mazda did decently well in Euro NCAP testing as a new car, there's now a 20 percent higher risk of death in the 2003-2008 Mazda due to the degradation of its bodyshell. In the rusty car, the chassis rail separates from the floor, the footwell ruptures, the sill gives way, the seat mountings move and the dummy's head hits the B-pillar; all important failures, despite Thatcham saying the cars actually performed better in the crashes than they expected with all the rust. But still, the corroded structure isn't able to transmit loads in the way it was originally designed to do. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. The Golf does significantly better — despite rust flakes flying when the Golf hits the wall — as the years have only caused it to lose a single point. An important thing to remember is that the cars aren't tested in comparison to corresponding new, 2018 cars: the tests are in reference to the crashworthiness standards in place when they were new. The cars' airbags inflate like they were supposed to, but on the Mazda the dummy's head bottoms out the airbag due to the car's structure failing, meaning the airbag cannot perform as designed. Driven cautiously, an older car is still mostly fine for driving around. But tests like these remind us that it's not enough that a car runs and drives, if the body has turned into Swedish knackebrod. And if you repair the visible rust and the structure underneath remains as compromised as ever, there's an ugly truth under all the bondo. Perhaps it isn't such a bad idea to have yearly roadworthiness inspections.

Volkswagen pushed back against Takata airbag recall

Volkswagen and Audi will recall about 850,000 vehicles in the US to replace their Takata-supplied driver side airbag inflators, but the automaker doesn't believe the safety campaign is entirely necessary. In a letter to the National Highway Traffic Safety Administration, the company pushes the agency to re-evaluate the recall's scope because the parts are allegedly safe, it claims. VW asserted in the letter, which NHTSA posted online (as a PDF) with other documents about the company's safety campaign, that the vast majority of the automaker's recalled vehicles used Takata inflators from the supplier's factory in Freiburg, Germany. Only the US-built Passat had components from Takata's plant in Mexico. VW's argues to NHTSA that its recall is unnecessary because there are no reported airbag ruptures in the German-made parts, and the plant has better quality control than Takata's factories in the US and Mexico. In addition, the Mexico-manufactured components in the Passat are also allegedly safe because they come from a time after significant upgrades to the plant to address humidity and welding concerns. "We do not believe the facts known to date support the scope as defined in the Takata defect notification," VW's letter says. To be clear, VW is not refusing the Takata recall and plans to fix the affected vehicles. Instead, this letter shows the automaker expressing an opinion that NHTSA's scope for the campaign is too broad. VW now plans to do its own analysis on the inflators to strengthen that case, according to The Detroit News. "We respectfully request that, should such results be shown, the agency work with Volkswagen and other manufacturers to revisit the scope of these recalls," the letter said. Takata's recalled inflators use ammonium nitrate as a propellant, and experts believe that long-term exposure to high humidity can make the chemical more likely to cause a rupture during airbag deployment. The spray of metal shrapnel from the exploding parts has links to at least 10 deaths. Related Video:

An inside look at VW's new California R&D center

Less than two months ago, the Volkswagen Group opened a new facility in Oxnard, California (about an hour's drive west of Los Angeles). The $27 million investment, touted as Test Center California (TCC), serves as a research and development lab testing emissions for all brands under Volkswagen's umbrella, including its newest member, Porsche. While still not fully operational, we toured the new 64,000-square-foot building last week and had a first-hand opportunity to see just how much work is involved testing engines and meeting increasingly stringent government emissions standards.
Replacing a similar facility established in 1990 in Westlake Village (about 20-minutes east of the new location), our guide explained how Oxnard was chosen for its temperate climate, varied regional terrain for test drives and low altitude. (The area is only a few feet above sea level - a critical parameter when instrument testing emissions.) The new facility is capable of analyzing hundreds of vehicles, prototypes and customer-owned vehicles, annually.
Most interesting to us was the huge stainless steel climate chamber, with a massive four-wheel dynamometer that allows VW to test running vehicles in both scorching desert and freezing climates without ever leaving the building (an Audi Q7 was running in place during our visit). We were also mesmerized by the countless storage tanks and intricate plumbing of chemicals, stored in both liquid and gas states, needed to perform the variety of tests. Lastly, we took a look at Bugatti's service center on the west coast, located completely within the new center. While there were no supercars on site, the facility is equipped with plenty of spare forged wheels (mounted with expensive Michelin PAX tires) and a Veyron-specific repair jig that allows the vehicle to be completely disassembled, if needed. It is a shame that the facility, which set off all of our automotive geek alerts, is closed to the public.