$30K Ford Ranchero EV Pickup - News & Info

[kvermeer]

Seriously. Pickups (& SUV's) went bad when soccer-mom's got tired of mini-vans...wanted "big & powerful", thinking that meant "safety"? I dunno. Get an 'effin' Suburban for your family.
...
Safety is cool. I like that there are fewer traffic (percentage-wise) fatalities and injuries now than there was 40 years ago.
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I get the safety thing, I don't get the "bigger, better, drives like a luxury car" thing.

What this analysis misses is that the Suburban or crew-cab Superduty is safer (unless it rolls) for those inside it, but less safe for those outside the vehicle. Pedestrian fatalities have been rising for a decade, even with our fancy AEB systems and backup cameras. It's a selfish arms race.

Also consider the huge cost of mismatched bumpers:



They're supposed to be the same height according to the standard:

https://www.ecfr.gov/current/title-49/subtitle-B/chapter-V/part-581

Except for trucks and SUVs:

For rulemaking as provided in part 552 of this chapter to exempt a class of passenger motor vehicles from all or any part of a bumper standard issued under this part on the basis that the class of vehicles has been manufactured for a special use and that compliance with the standard would unreasonably interfere with the special use of the class of vehicle; or

which are intended for off-road work on farms and such. In 1946, it made sense to use your Plymouth pickup to tow a trailer of workers across your farm field, and you wouldn't want it to have to comply with sedan regulations because it was for work. In 2026, that pickup is no longer really for special use.

 

[Kopsis]

Surprised I haven't seen this posted yet (or maybe I just missed it):

Unicast EV Truck Is a Manufacturing Marvel - Until You Try to Insure It After a Fender Bender

 

[kvermeer]

Surprised I haven't seen this posted yet (or maybe I just missed it):

Unicast EV Truck Is a Manufacturing Marvel - Until You Try to Insure It After a Fender Bender

They claim that instead of replacing a whole subframe, body shops will literally follow factory "dotted lines," cut out the broken piece with a saw, and install a service replacement part using rivets, structural adhesive, and bolts.

On paper, it sounds like a brilliant solution.

On paper, it sounds horrifying.

I hate steel because it rusts. Aluminum does not rust, and it's lighter! My father has an F250 with aluminum panels, it's pretty nice. His last one got totaled by hitting a deer.

But I love steel because it's ductile and weldable, allowing far better repairs than structural adhesive, rivets, and bolts. I understand that these new epoxies are miracle materials on the production line, but have these people ever been under a truck after a decade of Michigan winters? It's not going to work the same.

 

[Kopsis]

I understand that these new epoxies are miracle materials on the production line, but have these people ever been under a truck after a decade of Michigan winters? It's not going to work the same.

I've worked with some of the aerospace epoxies. They're amazing when used exactly as specified, but any deviation and all bets are off. Things like perfect surface prep, accurate mixing, maintaining optimal bond thickness, optimal curing temperatures, etc. are going to expensive if they're even possible. And unlike aerospace, I doubt anyone is going to do x-ray bond inspection to actually verify the repair.

 

[Rocks]

Things like perfect surface prep, accurate mixing, maintaining optimal bond thickness, optimal curing temperatures, etc.

None of these will happen at a body shop.

 

[kvermeer]

None of these will happen at a body shop.

If they're very, very lucky, the service bays will be heated. Maybe they'll hit it with a wire brush and a blow gun. Hopefully it holds until their warranty expires next week.

 

[AeroWolf]

Ford would probably sell you a special splint sleeve that contained the appropriate adhesive and support structure. Just slip it around the wire brushed and alcohol wipe cleaned composites to be bonded. Then apply a heat gun to activate the sleeve causing it to shrink while the adhesive starts bonding the composite parts.

 

[kvermeer]

Ford would probably sell you a special splint sleeve that contained the appropriate adhesive and support structure. Just slip it around the wire brushed and alcohol wipe cleaned composites to be bonded. Then apply a heat gun to activate the sleeve causing it to shrink while the adhesive starts bonding the composite parts.

Maybe I'm missing something, but you realize we're talking about the *truck frame* here, right? The one made from cast aluminum, not composites?

I do love heat-shrink sleeves for field-expedient repairs of wiring harnesses (though a Wago and some electrical tape is even quicker in the field), but you're not going to fix a casting with one.

 

[d.h.]

I've seen a lot of aluminum frame dump trucks, they're popular for their light weight. Those things go through hell, grossing 35 tons on and off road. I would rather think Ford has this figured out.

 

[AeroWolf]

Maybe I'm missing something, but you realize we're talking about the *truck frame* here, right? The one made from cast aluminum, not composites?

I do love heat-shrink sleeves for field-expedient repairs of wiring harnesses (though a Wago and some electrical tape is even quicker in the field), but you're not going to fix a casting with one.

My bad. It seemed like you were going into structural composite repairs. Not strictly metals.

 

[Kopsis]

I've seen a lot of aluminum frame dump trucks, they're popular for their light weight. Those things go through hell, grossing 35 tons on and off road. I would rather think Ford has this figured out.

Massive difference between a frame assembled by welding/bonding/fastening together aluminium extrusions, and casting the entire frame as one monolithic part (that's the new giga-casting tech Ford is touting).

And the viability of the cast frame as built isn't even being questioned. It's the repairability (and specifically the cost of the advanced techniques needed) that's the concern.

 

[atx_ev]

AI says replacing sections etc in the real world on teslas has actually been cheaper. And that low speed collisions result in zero damage in many cases. The sectioning model apparently does work well.

However independent shops have to spend 100K+ for tools and certifications. Plus 10s of thousands a year for recertification and recalibration each year. This means people will be going back to the dealer.

tesla repairs are cheaper than rivian repairs but tesla drivers crash more often (broader demographics, high torque) so tesla insurance is higher than rivian insurance.

 

[kvermeer]

AI says replacing sections etc in the real world on teslas has actually been cheaper. And that low speed collisions result in zero damage in many cases. The sectioning model apparently does work well.

AI says lots of things. Not all of them are accurate, so all of them are untrustworthy.

 

[Goodyear]

AI says replacing sections etc in the real world on teslas has actually been cheaper. And that low speed collisions result in zero damage in many cases. The sectioning model apparently does work well.

However independent shops have to spend 100K+ for tools and certifications. Plus 10s of thousands a year for recertification and recalibration each year. This means people will be going back to the dealer.

tesla repairs are cheaper than rivian repairs but tesla drivers crash more often (broader demographics, high torque) so tesla insurance is higher than rivian insurance.

Here is the ChatGPT AI answer:
Tesla Fender-Bender Repairs: Modular vs. Traditional Frame/Sheet Metal
For Tesla, modular replacement is often more expensive than traditional frame and sheet metal repairs — especially for minor fender-bender damage — because of how Tesla’s repair philosophy and part availability work.

Why modular repairs cost more
Tesla’s design and repair strategy often involves replacing entire modules (e.g., a front frame rail assembly, bumper fascia, or shock tower) rather than just the damaged subcomponent Tesla Service+1. This is partly due to integration of electronics, sensors, and structural reinforcements into single units, and partly because of limited aftermarket parts availability EVSpeedy.com. When a small dent or scratch occurs, a certified Tesla body shop may still order and install a full module to ensure factory tolerances, wiring compatibility, and software calibration EVSpeedy.com. This means you’re paying for the whole unit, not just the damaged part.

Traditional frame/sheet metal repairs
In conventional vehicles, a certified collision shop can often repair or replace only the damaged panel or frame section, using standard parts and techniques. This can be significantly cheaper — for example, a small dent above the wheel with paint touch-up might cost under $1,000, while a Tesla equivalent could run $5,000+ if a module is required Tesla Motors Club+1.

Cost data and trends

• FenderBender reports that many low-mileage Tesla repairs are so expensive that insurers write them off Fender Bender.
• EV repair costs are already higher than ICE vehicles — average U.S. EV repairable severity is about $6,018 vs. $4,696 for ICE Fender Bender.
• Tesla-specific studies show repair costs can be over 27% higher than the average vehicle, driven by proprietary parts, scarcity, and module replacement practices EVSpeedy.com.
• Anecdotal cases show fender-benders costing over $8,000 and severe collisions approaching $24,000 Fender Bender.

When modular repair is unavoidable
If the damage affects structural integrity, electronics, or sensors, or if the part is not available from independent suppliers, Tesla’s module approach is the only safe option. In these cases, the cost difference from traditional repair is likely to be substantial.

Bottom line
For a minor fender-bender on a Tesla, traditional frame/sheet metal repair is almost always cheaper than Tesla’s modular replacement approach — but only if the damage is limited to cosmetic or non-structural areas. If structural or electronic components are involved, or if parts are unavailable, Tesla’s method may be the only viable choice, even if it’s more expensive.

 

[Goodyear]

AI says lots of things. Not all of them are accurate, so all of them are untrustworthy.

AI is not necessarily "untrustworthy", but like any statement from an actual human being, the information needs to be verified and the sources questioned. A subject for a different forum.