Mach-E: Body In White

[@diskreet]

Great job Ben! You look so much more comfortable in front of the camera now. Thanks for taking the time to teach us

[@raddaks2039]

I'm getting a much deeper appreciation for how cars are engineered. That's a lot of stuff in there for crash safety. Thanks Ben, Sandy, and team!

[@codefeenix]

First car engineered for crash safety!

[@twany442]

That's why Volvo and the Mustang Mach E received top ratings from the IHS. The Volvo received an A+ and the Mustang Mach E received an A- because it didn't have the same headlights across all models. That the only reason the Mach E didn't receive an A+. You can check it out for yourself on the IHS channel.

[@twany442]

@@MM-ui9rm The more the merrier

[@twany442]

@@MM-ui9rm Elon Musk says Tesla's latest beta self-driving software is ‘not great’ "FSD Beta 9.2 is actually not great imo, but Autopilot/AI team is rallying to improve as fast as possible," Tesla CEO Elon Musk wrote on Twitter. Musk's critical tweet on Monday came just days after he touted Tesla's prowess with autonomous systems and components for them at an event called Tesla AI Day. Musk's critical tweet also follows the launch of a formal investigation into Tesla's Autopilot system by federal vehicle safety authorities in the US last week.

[@twany442]

@@MM-ui9rm I'm waiting on your comment to shut you down. Your lord and savior himself Elon admitted that Tesla's autonomous driving has flaws and it's not that good.

[@calebjones3383]

Ben seemed a lot more comfortable this episode, he seems to be fitting in more and appears more relaxed and into the flow. I liked how he took lead on the episode instead of waiting for Sandys every command. Good job Ben! ^w^

[@maxtorbelgium]

I would also love that Sandy would just stand on the side and just do intro and outro…. And the keep quiet while Ben does his thing. Him always interrupting is so freaking annoying

[@Cloxxki]

Soon he'll have his own radio show on which he won't play any music and just yap away cracking jokes :)

[@maxtorbelgium]

@@Cloxxki what jokes ????

[@nononsenseBennett]

He is very knowledgeable. That company is awesome. Such interesting content

[@opennetus]

I've really appreciated your Mach-E teardown videos. As a non-engineer, it is interesting learning about what goes into design an electric car. Thank you and great job!

[@JohnPMiller]

13:05 Congratulations to the Ford engineer who used scalloping in the front seat mounts!

[@1djbecker]

That was probably the result of collision simulations. Scalloping the edge is stronger and potentially has more consistent strength. It allows stretching metal to spread the force over more of the spot weld, in part by reducing the leverage of a straight edge, reducing the peak stress. They didn't do it elsewhere because the cost saving of using a straight edge was more important than increased strength and very slightly decreased weight.

[@JohnPMiller]

@@1djbecker Very interesting! Thank you.

[@TheJoeSwanon]

@@1djbecker it amazes me the amount of tiny engineering details that goes into these vehicles

[@aweiwei1987]

@@1djbecker i agree on you. it must be a crash energy absorbing concern here，while Japanese cars like to scallop edges to reduce weight，and they do it on every single edges they could

[@Charles-tq9tc]

I have some experience in textile, square stamps are harder to make than round stamps. What’s surprising is that they are using stamping rather than multilayer knifing.

[@midlifecrisistime]

Always a good day when Sandy puts out a video 👍

[@MunroLive]

Enjoy!

[@MacEliot]

Indeed

[@handle_unknown]

Ye!

[@davidanderson1060]

Sandy it was really interesting to learn where the term "Body in White" or BIW came from. But you forgot to mention what it actually is! That it's the fully welded/glued/riveted body or unibody before anything gets bolted to it. :-)

[@andyonions7864]

Converting metric to pounds is easy. Double it and add 10%. e.g. 30kg, x2 = 60, +10% = 66lbs.

[@AndyZach]

Right! I remember 1 kg=2.2 pounds.

[@userasdf1546]

I always doubled to get a rough estimate

[@Mental_Egg]

Love learning how cars are engineered.

[@alfredogonzalez1280]

I would have liked to see a comparison between the weight of the BIW of the Mach E and the Model 3 or Y. When the crashworthiness tests come out, you could check structural efficiency.

[@chrisbraid2907]

I think Tesla took the lead on crash safety looking at the testing results and this is Fords Electric car response. A good attempt in steel by Ford but I think it would be unfair on Ford to compare it with the model 3 or Y . Especially against a gigapressed Chassis …

[@grahammonk8013]

I checked the weight of a LR model Y, and it's 4415 pounds. The weight of the heaviest Mach-E is 4890 pounds! Structural efficiency is an interesting term, I would like to see this as well.

[@AbcAbc-be7ku]

I enjoy Sandy’s use of technicality correct terms such as “dumb dumb”-- that is how I “engineer “ in my garage at home

[@GrandHuevotes]

keep in mind IIHS is soon launching side impact 2.0. it’s going to be very aggressive. car makers will need to change the side structures particularly the doors. early findings are that side doors are being penetrated too easily and too much (with the new tests) however with the pillars being fairly strong.

[@markusdd5]

"You could tie the Queen Mary with that thing!" It might not be the most weight efficient, buit it seems Ford at least did not cheap out on NVH and Crash stability on that hting, which I think is good.

[@leerjet1868]

Tow.

[@sotek2345]

Have a Mach-e GT on order for my wife. This video made me very happy given everything they did for strength and safety.

[@paulkieffer1189]

Can’t wait for the PLAID!!!!

[@Puzpo]

My body is ready!

[@ptrsrrll]

Don't hold your breath..

[@stephen8623]

Me too. Then we will see some real innovation and quality materials...not just a load of stamped sh*t metal.

[@GrandHuevotes]

fun fact Honda and Volvo were some of the first to do “shotgun” tie ins around 2012ish. Honda with its ACE structure and volvo as well. early thinkers.

[@codefeenix]

2012 is not anything near early for those ideas

[@americanrambler4972]

I stopped into my local Ford dealer to look at one of these Mach E’s they had on display. I was surprised how small the door openings were and how high the step in over the door sills was. Overall, I felt “cramped” inside because of the door opening width and the head banger low upper door jam height. Now I see why. This thing is built like a literal tank! It will be interesting to see how these hold up in real world crashes and if they get repaired or scrapped due to what it will take to repair them.

[@Elkarlo77]

A modern Car which went into such a Crash needs to replace a lot. Btw.: kzbin.info/www/bejne/d4CYhomXfax6iNk here are the Videos of the IIHS Crash, afaik it had 2 Problems: Some Basic Headlamps were not perfect and some Access Problems after the Crash, but still above average in both points. For the repair part, my Ex-Girlfriend crashed a Skoda (VW) into the main traffic bollard with the main Batterie for the whole Chain and it seemed not to bad, but we had to replace a lot of the frontal Section to get it passed the 2 year inspection here in Germany. Crumble Zones are like Crash Helmets, after the first accident they need to be replaced. The same on my Mondeo (Fusion in US) when a car crashed into my rear, they had to cut off all of the crumble elements and mount new ones. But the White Body was protected and everything straight.

[@budgetaudiophilelife-long5461]

👍🤗THANKS AGAIN FOR YOUR HELPING US GROW IN KNOWLEDGE AND UNDERSTANDING 💡😎 I had to chuckle when Ben referred to the Taurus as a big car …since we drove a 79 TOWN CAR thru most of the 80s😉 And we keep tipping the the cashiers and enjoy the smiles 😊😍😍😍

[@lengould9262]

Promoting a tipping culture outside of restaurants is an error. Here we expect employers to pay a fair living wage, and polite efficient service from trained people to be the norm if they want our business.

[@casperhansen826]

The cashiers probably has the lowest income

[@lengould9262]

@@casperhansen826 Tipping's a poor solution.

[@joshgray1331]

Sandy, nobody can replace you! I hope you stick around. Your crew is solid, but every vid shows that you are the wizard! Had a mechanical engineering prof like you...no BS, hold yourself accountable for your design decisions. He also is an expert witness and has roasted many engineers for basically not saying "I don't know". Thanks!

[@Urgelt]

So, aside for some missed opportunities for weight savings, the body-in-white looks pretty good. It is purpose-built for a BEV, Ford didn't just rip off an ICEV body-in-white and make a few changes to it. Credit where credit is due!

[@markplott4820]

True, it's definitely not a Mustang body or a SUV Truck body. but, it's still less Advanced than Tesla.

[@ranig2848]

Not really. Weight is BEVs worst enemy. It’s poorly designed in the most important aspect of an EV. They basically just tried to make it work. Had to add more safety features since it was too heavy which made it even heavier. Clearly, Ford has no idea how to build electric vehicles and how to ensures all teams are coordinated to reduce weight and complexity. Every engineer know building complex things is easy. Simplifying is the real challenge and that exactly where Ford failed to deliver.

[@Urgelt]

@@markplott4820 It's too heavy. But the first Model 3 body-in-white was too heavy, too. Way too many parts and too much welding. For a first stab at a BEV, Ford didn't do badly at all on the body-in-white. Just shave some weight and it's competitive. Tesla is *still* working on ways to reduce the weight of its vehicles. It's a work in progress. It's the HVAC, electrical wiring, software and fasteners where Ford lags badly. Meh, encapsulating Ford's tech lag can't be done in a sentence, but that's my too-brief stab at it.

[@markplott4820]

@@Urgelt - the difference is, TESLA after the 2018 model 3 teardown, in 3 months went to only a 3 part casting, reducing weight, parts, welds and fastener. and the Model Y , improving even further, with Single rear casting, that NO other OEM uses, to build a BEV.

[@Urgelt]

@@markplott4820 That is kinda sorta my point. Tesla came out with an overweight Model 3 with too many parts, then got right to work to improve it. That's still ongoing, but they've made a lot of progress. Ford came out with an overweight Mach-E with too many parts + energy inefficiencies in the HVAC and electrical systems. So what's the plan? I won't count Ford as dead until it files its bankruptcy paperwork. Until then, I am hoping that they will lean into BEVs hard and get the improvements they will need to have a shot at surviving this disruption. 'Cause if they don't, they won't.

[@mukamuka0]

Always love history told by Mr.Munro 😁

[@mukamuka0]

Love to see your comment on Elon's 5 steps of engineering 1 - Make the requirements less dumb. 2 - Delete the part or process 3 - Simplify or Optimize the part or process 4 - Accelerate cycle time 5 - Automate He said this in one of Tim dodd video

[@radimbosticka]

Sandy: I will let Ben do all the talking. Sandy 30 seconds later: maybe not :D Just stay with conversation guys. Great insights!

[@AndyZach]

I'm learning a lot about car manufacturing. Sandy can always suggest a better way to do almost every engineering decision.

[@martinultimatevw3779]

Ben in his casual presentation.... Sandy "oh wow look at these roofrails" 😂😂🙈 look at ben's face 😅😂👌

[@stevethomson6900]

Ben and Sandy - Another great informative video. I feel like engineering schools should make Munro Live mandatory viewing.

[@fred993a]

Sandy - you are providing an engineering education that one can't get anywhere else! Thank you!

[@rmeden1]

Great job Ben. You seem to be getting more comfortable.. no question you know your stuff, love your analysis! Sandy, try not to interrupt... Ben knows his stuff and will swing it back to you. Thanks for the BIW explanation.. I was about to look up the history when you started with it.

[@w0ttheh3ll]

Surprised that Sandy didn't complain about the tiny extra windows behind the C pillars. They don't look very useful and surely add weight and expense.

[@flyfishing_and_hiking]

Sandy didn't seem to like the "shark fin" for the rear seat. I guess that it has this dimension in order to support luggage load in a front crash load case and/or fulfill the luggage retention regulation ECE R17.

[@flyfishing_and_hiking]

@David No I don't work at Ford , but I have worked with crash issues for other OEM:s in Europe for more than 20 years.

[@mjcamp01]

@@flyfishing_and_hiking I got the impression others manage it with a much smaller fin though, after all, it's not the size, but what you do with it

[@flyfishing_and_hiking]

@@mjcamp01 All OEM:s don't have the same internal requirements. Some might have req. which exceeds those of rating and/or legal requirements regarding crash, so it depends. The shark fin might be too bulky, but it's not necessarily so.

[@MbeyaIsHome]

Ben is talking at medium speed, steady and calm. Well done.

[@russellr1677]

Superb presentation Ben - thanks!

[@carlstockmal]

Thanks, kids! I got my MunroLive bumper sticker and am proudly displaying it! I saw on Transport Evolved that there's a company making trailers with a battery pack in the trailer so that it doesn't drag from the towing vehicle. I wish Munro Live would have a sit-down-and-engineer session and talk about how a self-propelled trailer could work and the potential benefits of self-propulsion, self-braking, adding range to the towing electric vehicle, adding solar panels, and how that could all work as a unit.... maybe THAT's how we get to a 1000 mile BEV...?

[@johnb7430]

1000mile bev? Maybe. A trailer that costs $30,000 instead of $10,000 definitely.

[@amimartian]

No silly music and a lot of talk on point - keep that coming!

[@nickfosterxx]

Glad you dropped the pointless few bars of intro music and just jumped straight in this time. And thanks as ever for another informative video.

[@W9KB]

This vehicle was likely computer modeled using finite element technology and all loads and stresses evaluated under various loading conditions… the days of too much metal are usually seen in the rear view mirror. If something looks too beefy (e.g. shark fin), you likely haven’t considered all the design load conditions and/or criteria. Regarding NVH, I removed the rear fiberglass ‘belly’ cover to install a Torklift trailer hitch… while off for few days and I was quite surprised about how effective it was for reducing motor/gear whine. Kudos to the Ford NVH team for their outstanding job on the MME!

[@devonbikefilms]

Thanks for taking the time to do this. Fascinating to see something outside my own industry. Every day can be a school day. Much appreciated.

[@carlotonydaristotile7420]

Best show on KZbin.

[@enyotheios2613]

Love it! This kind of video is catnip for engineering nerds like myself. Totally appreciate the breakdown and visuals! ❤❤❤

[@stprinz]

"You can definitely tow the Queen Mary with that thing." 😂

[@atkakukac]

Great PR stunt opportunity for Ford right there, courtesy of the one and only Sandy Munro.

[@theoldman8877]

No , it is not strong enough for any serious naval tow operations. I did notice that there was only the one anchor point of that type on the structure. So it must restrain all back seats and passengers that could be as much as 800 pounds multiplied whatever the g-force is. That is a serious amount of stress.

[@nononsenseBennett]

HUGELY beneficial and interesting. Thanks for taking the time to show the world the magic of the engineering process.

[@laplacesdemon45]

thank you Sandy and Ben

[@twoo1998]

Mustang Mach E IIHS results (Tesla Model 3 numbers are in parentheses) : roof strength 6.21 (5.85), Small Overlap crash Driver head HIC 80 (88), Small Overlap Passenger Side: passenger 85 (54), driver 62 (66). Moderate overlap driver HIC 125 (177), Side crash: Driver Head HIC 140 (237), rear Passenger Head HIC 34 (78)

[@nihongobenkyoshimasu3190]

2:01 When comparing the total weight between different vehicles, it would have been interesting to compare the weight of the body alone. If not available, just substracting the weight of the ICE motor and gear box for the Taurus and F 150 to have a better idea compare to the Mach-E 800 kg / 880 lbs.

[@matthewclark1785]

I like Ben, he reminds me of Norm from old school “This Old House” episodes :)

[@lsauve]

Safety first, always wear these : safety glasses

[@matthewclark1785]

@@lsauve lol

[@kentberg417]

Enjoyed this video. Looks like a strong albeit heavy base to protect occupants and power source. There are again opportunities for Ford engineers to reduce weight and other improvements. Hopefully lessons that they will implement in Mach IIe.

[@axeman3d]

It's like an armoured car, apart from the one dude who did his scalloping.

[@wongman2001]

I really wasn’t interested in unibody designs till now, thanks Ben & Sandy

[@PhotoHoag]

Great job Ben!

[@tpgsoldier]

I'm a simple man. I see Sandy I click.

[@MunroLive]

Way to click!

[@algreen1]

Nice, thanks for sharing. Good team member you have there too

[@seasong7655]

The person doing the seat mounts must have been too afraid to tell the others they were doing it wrong.

[@twany442]

F Talk to tesla about the booster seats in the Model Y

[@troyguyer9194]

Or they could make a front and rear mega casting. 🤔ii heard of someone else doing that currently.

[@patreekotime4578]

Megacasting replaces almost none of the components they talked about today. It ties into the tusk and shotgun but is specifically dealing with suspension and drivetrain and things underneath. The rear megacasting includes a cross beam that would be directly behind the rear seat bracket. But it doesnt really go up into the quarter panels.

[@MrFoxRobert]

Thank you!

[@rmd6483]

Thank you for what you do. No other channel like this! I have more appreciation for Ford chassis. More robust than Tesla, IMHO. Castings have no damping and fracture. Also considering this is their 1st iteration. I'm sure more weight savings coming.

[@zezizarjaars]

And Tesla is just planning; one cast, two cast, battery, click click click, done?

[@miltonmiller]

Now that we have seen what a casting looks like, a body in white build the old way looks so complex and even weird...

[@joeyscleaninglady2877]

engineers made a run to home depot to improve NVH on mach-e

[@twany442]

The same place your mother used to work cleaning bathrooms.

[@AngelGschannel]

Bang up job! 🤣🤣🤣 Nearly spit my coffee again!!!

[@johnnyb8629]

they are going to make great cop cars for state troopers. I can see these doing pit maneuvers on just about anything on the road less a semi truck. ok, i want a mad max remake done with all the EV on the market today,lol

[@Dave_thenerd]

They're gonna have to compete with the Cyber Truck Police Car concept though.

[@craigring153]

How are the roof loads handled when the Pano roof is optioned? Are the roof rails replaced with another load path?

[@wagg8989]

I’m tagging this question. Hope they answer that question as most of us have the Panoramic sunroof

[@FamilyFirstJ]

So much knowledge for free! Thank you guys so much ...if only Jack Rickard was around to witness this

[@mellis966]

Thanks a lot for this review guys. Very informative!

[@Tysto]

This body is amazingly clean. I would have thought there would be residue all over from the glue used to stick down the carpet, soundproofing, etc.

[@Mark-M72]

spotted my first one on the road in the UK just a few days ago. well in a car park . .does look good

[@mec7568]

Interesting the amount of effort invested to protect the large-footprint flat batteries vs what was needed for a moulded fuel tank located well inboard of the perimeter.

[@markedwards4879]

Great to hear you talking in proper metric engineering units :D

[@josandragos2962]

Good job guys. I really enjoyed it. Thank you.

[@CptTrips89]

12:42 he is talking about the Anti-Flutter glue and standard to apply on all vehicles with a roof panel

[@Ryan-dz3jo]

Thanks team, nice work.

[@cbromley562]

Well that's all reassuring. Thanks for the mosey round, looks substantial.

[@rogerpoppen2651]

I'd like to see comparisons with Model Y and id4 as far as weight, complexity, etc.

[@DarkBrandon1]

Need an entire episode on the NVH of the vehicles

[@louspinelli1745]

I love your tireless work ethic to reveal the truth to your starving audience! Your team is a role model for others to mimic! Heartfelt thanks.

[@MunroLive]

We appreciate that!

[@totaltimepass001]

7:05, “they do origami” 🤣

[@UOTCbassist]

If you've ever felt insignificant, just look at those c-pillar windows

[@rgeraldalexander4278]

Fabrication of the body in white is an area Ford has loads of experience with...looks strong if heavy.

[@Firestorm637]

Unibody absorbs crashes better vs cab on frame trucks. Rigid frames transfer energy to passenger compatibility.

[@Lolo-uk4rb]

I'm wondering what the results will be of the EuroNCAP crash-tests. They have (at this moment) the most strict tests.

[@jrpeet]

The tire noise thing ... looks like "Mr Pillow" reject :)

[@rebellionair3]

Curious how BIW weight compares to Model Y BIW

[@ironrje]

Yes tell us sandy.

[@aweiwei1987]

Ben is a professional body engineer， hope he could dive into more details about mach-e.

[@mefobills279]

BYD blade battery is structural and uses Li Iron Phosphate. They do a nail puncture test and the batteries don't go into thermal runaway.

[@Thatdavemarsh]

We always called the thumbable putty for the rat holes the ‘dumb-dumb’, not the expandable adhesive. Neat how terms are flexible.

[@paullester2535]

thoughts on the rear inner Y-structures - contributing to torsional stiffness?

[@TehCoz]

Great job by Ben and his team on the teardown. Would be interested to know how that BIW weight compares to the Tesla Model Y? Thanks.

[@markplott4820]

Model Y is 1000 lb less weight, but stronger. the Y roof alone can support several Mach-e stacked on top

[@luisdetomaso2224]

@@markplott4820 Right, I'm sure the Tesla roof can support 13,500 pounds. Your comment is pure genius

[@rabidsquirrel22ben]

@@markplott4820 the Model Y is 400 lbs lighter than the heaviest configuration of the Mach-E. The rest of your comment is nonsense.

[@Max_xaM]

@@luisdetomaso2224 The Model3 has a roof strength rating of 20,835 pounds. Source: www.iihs.org/ratings/vehicle/tesla/model-3-4-door-sedan/2021#roof-strength

[@markplott4820]

@@rabidsquirrel22ben - Muck-e is a GARBAGE 🗑️ car. and FUD motors doesn't even break even on it.

[@johntrotter8678]

I hate to be a Tesla fan, but the relative complexity of the Ford approach compared to massive front and rear castings, the structural battery pack, and an all glass roof is notable. Piece count anybody? Thanks for the detailed explanation in any event.

[@lightman489]

I used to think it was a flimsy dangerous vehicle but these brake down video have changed my mind on the mach e im pretty sure if it hits a telephone pile it's knocking it down and a f150 is no match for it in an accident

[@rwdplz1]

There may be room for improvement, but it appears to be the best designed part of the car. Probably because it's still mostly conventional design. Ford only seems to have failed miserably on the electric vehicle specific bits.

[@Heckofadeal]

Very informative !!!!

[@createdeccentricities6620]

As a consumer I really do want a vehicle whose design lends itself to protecting me and my passengers, in the event of a crash.

[@mikemccarthy1638]

Well, it seems you better buy an EV, cuz you (also) benefit from the structural reinforcements…

[@Robbie6298]

At Ford the engineer that designed the scalloped seat mount got rewarded by 5 extra minutes for lunch hour last Tuesday and a "keep up the good work Bob". While Jim Farley expenses the company for a $1000 business lunch.

[@abraxastulammo9940]

10:55 And that, boys and girls, is why the VW battery has those structural enhancements inside: with the (structural) battery disassembled from the underbody you are not allowed to enter the vehicle anymore.

[@maxtorbelgium]

Munro: why don’t you tell me about it Ben …. Ben: well this is the…. Munro - starts blabbing again. LET THE MAN SPEAK !!!

[@thedownwardmachine]

How does the weight of the Mach-E BIW compare to a similar ICE vehicle, like the Taurus? The total weight was compared but not the BIW.

[@A2an]

Just lovely, really good video, thanks for the efforts 👍

[@romankrucker]

On this Mach E and as well on the Teslas there seems not to be very professional pvc seam sealing on these BIW. You can see this manually applied seams on the dash panels as well on the wheel arches in the back. Robitic applied seams are standart on german cars and it is needed for rough winters and rust protection.

[@caesssmack76]

When I was younger a "body in white" was a bare bones body only that could be special ordered that came painted in basic white paint. Hence the name, BODY in WHITE. These were purchased by race car people that wanted to be able to make the necessary modifications needed for their cars they wanted to build from the ground up. It's always been confusing to me to hear Sandy and crew refer to the cars they are using as body in white cars because , one they are not body shells and two, they aren't white.

[@axelliljencrantz4462]

Sandy was pretty critical against the Model 3 because the BIW was too stiff, used too much high strength steel and could be made both lighter and cheaper. The same seems to apply to this BIW, but Sandy seems a lot happier with it. I'm curious as to what the difference is between this BIW and the Model 3 to make one bad and one good. Thanks!

[@Steph1]

Tesla: we do everything to protect the people Ford: we do everything to protect the battery