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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.

GM is the latest automaker accused of diesel emissions cheating

Volkswagen and Ram need to make room on the diesel-emissions bench for General Motors. America's largest automaker was accused in a lawsuit on Thursday of rigging hundreds of thousands of diesel trucks with at least three so-called defeat devices to ensure that the trucks would meet federal and state emission standards, even if they generated more pollution in real-world driving. According to the complaint, on-road emissions testing conducted for the plaintiffs found that Duramax-equipped trucks produced NOx pollutants, comprised of nitrogen and oxygen atoms, two to five times higher than legally permitted, and "many times" higher than their gasoline counterparts. The proposed class-action lawsuit was filed in federal court in Detroit on behalf of people who own or lease more than 705,000 Chevrolet Silverado and GMC Sierra pickup trucks fitted with "Duramax" engines from 2011 to 2016 model years. The lawsuit seeks remedies including possible refunds or restitution for lost vehicle value, plus punitive damages. It adds to legal problems for Detroit-based GM, which has already paid about $2.5 billion in penalties and settlements over faulty ignition switches linked to 124 deaths. GM joins at least five automakers whose diesel emissions have been scrutinized by regulators or consumers. They include VW, which has admitted to cheating; Mercedes-Benz parent Daimler; Fiat Chrysler Automobiles, Peugeot and Renault. GM spokesman Dan Flores called the claims "baseless," and said the trucks comply with US Environmental Protection Agency emissions standards and California's own tough standards. Shares of GM were down 69 cents, or 2.1 percent, at $32.50 in afternoon trading, after earlier falling to $31.93. The GM lawsuit was filed by several law firms, including Hagens Berman Sobol Shapiro, which helped reach multibillion-dollar settlements with VW on behalf of drivers and dealers. The case is Fenner et al v General Motors LLC et al, US District Court, Eastern District of Michigan, No. 17-11661. The named plaintiffs are Andrei Fenner of Mountain View, California and Joshua Herman of Sulphur, Louisiana. They said they would not have bought their respective 2011 Sierra and 2016 Silverado trucks, or would have paid less for them, had they known about the alleged rigging. Joseph Spak, an RBC Capital Markets analyst, in a research report said "negative publicity" from the lawsuit could drive buyers to trucks from Ford or even Fiat Chrysler's Ram.

2019 GMC Sierra Denali MultiPro tailgate and CarbonPro bed explained

When the 2019 Chevy Silverado debuted at the Detroit Auto Show in January, GM's Mark Reuss promised that the new 2019 GMC Sierra would have some significantly different styling and features than its corporate sibling. Previously, the Sierra has been little more than a Silverado with new front and rear fascias and some extra chrome inside and out. Well, Reuss was right. In addition to new sheetmetal, the Sierra exclusively gets the slick MultiPro tailgate and CarbonPro carbon-fiber bed box The tailgate really is trick. At the debut, GMC had multiple demonstrations, with engineers walking us through all six different configurations. Like all Sierra tailgates, the MultiPro version uses an aluminum skin to reduce weight. It's easy to tell which tailgate is which, as the MultiPro has a distinct cutout in the middle where it can fold down or extend. It can be used to extend the bed, drop to allow easier access, provide a sort of workbench, or be used as a step to help get into the bed. Yes, there's even a handle. Ford who? The step itself can support up to 375 pounds, 75 pounds more than Ford's similar tailgate step. This tailgate really is unique to the Sierra and is standard on SLT and Denali models. That said, the power-operated tailgate from the Silverado won't be coming to the GMC. Chevy gets its own exclusive, too. The Sierra's other big exclusive is the carbon-fiber reinforced plastic bed box. CFRP replaces steel inside the bed though not on the fenders. The bed uses four pieces; one for the bottom, one in the back and two along the sides. This isn't a CFRP. There is no steel hiding underneath these panels. Just take a peek underneath. The bed is a composite that uses 1-inch carbon-fiber threads, not a weave. Sheets of CFRP are molded and quenched — a process where the plastic coagulates and solidifies, locking in the carbon fiber — in just 60 seconds. That allows GMC's supplier to crank out these much more quickly. The finish looks like black fiberglass, though an engineer said that this wasn't the final production version. The final model will have different textures in order to improve grip and keep things from sliding around. GMC is touting the material's dent and corrosion resistance, though it remains to be seen how well it holds up to cracking. A video at the reveal showed people going after it with hammers and cinder blocks, but in-person demonstrations weren't available.