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imboden013

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I just found out how cheaply made the maverick is made. Today I topped a steep bridge overpass to find a huge chunk of 18 wheeler tire in my lane. Was way to late to avoid it, sounded like I’d hit a bomb. Was able to keep control and pull over at end of the bridge to look at damage. Under body protective cover half ripped from the floor pan and vapor canister dragging on road and paint chipped all along lower side panels. When I say protective cover ripped from underbody I mean ripped the studs(which look like 1/8 bolts spot welded to bottom of floor pan are ripped almost completely off and there are holes in the floor pan. Floor pan is paper thin. The protective cover’s mounting holes are ripped out. Check engine light is on. Mechanic at ford dealer says likely due to vapor canister is destroyed. I do know the mounting points on canister is broke off. Amazingly. The Mav stills run fine and tracks strait down road with no vibration or shimmy as I was able to safely drive it to the local ford dealer for them to look. Estimated cost to repair $1000. There goes my fuel savings for next 2-3 years. I think my mav was mad at me because I mentioned trade for a 1st edition at a nearby dealer.
I had the exact same experience except I came around corner and crashed into a concrete boulder laying in the middle of the road that had been kicked up from a piece of the bridge falling apart. The plastic shield on the bottom of the car was ripped off. The vapor canister was punctured. The service engine light came on. I bent a rim and popped the tire. It cost $2,300 to get repaired. Ford did a good job of fixing it. I'm in the process of trading for a 2024. Lol.
 

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Skid plates?? I didn’t see anything I’d call a skid plate on my mav nor the FX4. Both had the fiber, felt covers .
Fiber, felt, plastic ones are called "splash guards or air dams" and deflect small things and water as extra benefits to their main purpose to reduce air drag.
 

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Road debris can be a problem and very destructive . hit a semi brake shoe with toyota small p-up years ago . fortunately a couple of dents on underbody and oil pan . another time had semi (ups double trailer )blow tire in front of me . damaged front of truck . ups driver was able to control and pulled over
. ups covered damage and I replaced my underwear . learned not to drive near a semi .
Once while In my chev luv pu I drove at 60 over a semi spring leaf lying in road. Must have cleared it's raised end by 1/4" was afraid it would hang on something and come up through floor!
 
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imboden013

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I had the exact same experience except I came around corner and crashed into a concrete boulder laying in the middle of the road that had been kicked up from a piece of the bridge falling apart. The plastic shield on the bottom of the car was ripped off. The vapor canister was punctured. The service engine light came on. I bent a rim and popped the tire. It cost $2,300 to get repaired. Ford did a good job of fixing it. I'm in the process of trading for a 2024. Lol.
Was that a Mav also? I’m wondering how they will reattach the shield as the studs for attachment are ripped almost off the floor pan and it’s super thin.
 

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I used to work for a fleet of transfer dumps and it's never pretty when one of their tires blow.

See all kinds of stuff in the middle of the road where I live too. Had to stop more times than I can count and walk back to remove debris. It's pretty bad. Usually animal's though. But sometimes that's all it takes... a piece of bone or something small to cause a major accident. I refuse to be one of the drivers on the road to just pass stuff by like that. Especially on rural single lane highways. I'd rather pull off and walk a quarter mile back to the debris through the woods if I have to. Sorry this happened to you. That truck it was from should have policed their debris even if it went back a mile.

Anyways, will insurance cover you?
I appreciate that you clean up the debris. Very few professional drivers seem to do so. I recently drove I-94 between Minneapolis and Milwaukee. Heavy truck tire fragments at least every couple miles. Not to mention the deer carcasses almost a frequent as mile marker posts. I even saw a drive shaft. Who loses a drive shaft and doesn't pick it up?
 

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This whole thread is off base in my opinion. Engineering in general is about optimizing the solution for the "normal use" requirements. In the automotive engineering discipline specifically, taking weight out of the vehicle is almost a religion - because weight is the enemy of every kind of performance.

So having a thin floor pan isn't necessarily a bad thing. It's a smart way of taking weight and cost out of the car and giving all the Maverick owners the mileage they so much love. A road obstacle punching through the floor of a vehicle made for the road is very much an edge case that no OEM is going to design for. They're designing for MPG, for SORB and other crash protection tests, rigidity, etc.

You want thicker steel in non-critical areas of your Maverick? Sure. Just give back the great mileage. Give Ford more money to buy thicker gauge steel. Have a worse handling vehicle. Watch the weight balloon because weight begets weight.

The lunar rover was paper thin. Because that was the smart design solution. Your Maverick is paper thin in non critical places for the same reason.
 
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imboden013

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I appreciate that you clean up the debris. Very few professional drivers seem to do so. I recently drove I-94 between Minneapolis and Milwaukee. Heavy truck tire fragments at least every couple miles. Not to mention the deer carcasses almost a frequent as mile marker posts. I even saw a drive shaft. Who loses a drive shaft and doesn't pick it up?
I-40 gets a large amount of 18 Wheeler traffic and has a lot of tire debris. Usually smaller stuff of a foot length or so, I was unfortunate enough to find a much bigger piece with the bottom of my Maverick. I saw it flying out the back of it in my rear view mirrors looked to be 5-6 ft long. I know it did a number on the bottom of the Mav. Ripped the middle drivers side shield nearly plum off, broke the mounts(which don’t look like much as they look like 2inch long 1/8 inch threaded studs popped riveted to floor pan and busted the vapor canister and ripped it’s mounts off. I sure hope Ford can fix the studs so they don’t rust out the floor pan. That floor pan is so thin I’ll bet rusting out is going to be problem on the Mavs.
 
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imboden013

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This whole thread is off base in my opinion. Engineering in general is about optimizing the solution for the "normal use" requirements. In the automotive engineering discipline specifically, taking weight out of the vehicle is almost a religion - because weight is the enemy of every kind of performance.

So having a thin floor pan isn't necessarily a bad thing. It's a smart way of taking weight and cost out of the car and giving all the Maverick owners the mileage they so much love. A road obstacle punching through the floor of a vehicle made for the road is very much an edge case that no OEM is going to design for. They're designing for MPG, for SORB and other crash protection tests, rigidity, etc.

You want thicker steel in non-critical areas of your Maverick? Sure. Just give back the great mileage. Give Ford more money to buy thicker gauge steel. Have a worse handling vehicle. Watch the weight balloon because weight begets weight.

The lunar rover was paper thin. Because that was the smart design solution. Your Maverick is paper thin in non critical places for the same reason.
I’d give up a few mpg to have. A bit more steel under my feet. That stuff was super thin. A bit thicker than one of those old beer can pop tops but not much.
 

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It's not just the Maverick, or Fords. Each new generation of any vehicle seems to get thinner sheet metal than the prior. There's a reason a '73 Impala was along the lines of 4500 lbs, a '79 3900-4000, even back then they were dropping weight.

Check out a recent Toyota, Honda, or Subaru, the metal continues to get thinner. - My wife's Crosstrek doesn't feel any thicker, and it's definitely thinner than my '12 Outback. (Newer Outbacks also feel to be thinner metal, close or on-par with the Maverick btw).

While safer with the 'crumple' zones, they're totaled from what may have been minor damage in prior generations. Gone are the days where the safer vehicles were built like tanks. Maybe its safety, but more than likely in the name of fuel economy.

Want to watch a fun test, watch IIHS test of an F150 loaded with the weight of the Lightning's battery pack in the bed. It literally tears through the bed wall, through the cab's rear wall, and nearly comes out the windshield during the crash test.
 
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Was that a Mav also? I’m wondering how they will reattach the shield as the studs for attachment are ripped almost off the floor pan and it’s super thin.
They will order you a new one - for $100 bucks
 
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Insurance may cover it if, "the tire tread blew off a truck directly in front of you when it had a blowout." 😉

If it is just laying in the road and you hit it, it's very possible they won't pay for it.

Source: happened to me once.
Yea especially the wide base tires.




That sucks. I'd just say "The truck kept going, I had to stop immediately".
Mav brought us home no v
They will order you a new one - for $100 bucks
floor pan and those broke off studs is what I’m concerned about the evap canister and felt/fiber shield no big deal
 

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Mav brought us home no v

floor pan and those broke off studs is what I’m concerned about the evap canister and felt/fiber shield no big deal
oh - the felt under liner is $100, The Evap canister was $513 - they can repair the sheet metal, you probably will be amazed by that. The studs will need to be rewelded and I think they can do it. Mine would have been covered by comprehensive insurance, however, with a $2,000 deductible - I just paid out of pocket for all the effort it would have been. I did mention a concrete bolder came flying at me when an 18 wheeler bounced across the expansion joint on a bridge... Terrifying. Blew the tire out and bent the rim on the left front tire as it tore the bottom of my car out.
 
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imboden013

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oh - the felt under liner is $100, The Evap canister was $513 - they can repair the sheet metal, you probably will be amazed by that. The studs will need to be rewelded and I think they can do it. Mine would have been covered by comprehensive insurance, however, with a $2,000 deductible - I just paid out of pocket for all the effort it would have been. I did mention a concrete bolder came flying at me when an 18 wheeler bounced across the expansion joint on a bridge... Terrifying. Blew the tire out and bent the rim on the left front tire as it tore the bottom of my car out.
Sounds like your Mav sustained more damage than mine. My wheels and tires didn’t get damaged. Drat, no excuse to get rid of stock Lariat wheels and Michelins.
 

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oh - the felt under liner is $100, The Evap canister was $513 - they can repair the sheet metal, you probably will be amazed by that. The studs will need to be rewelded and I think they can do it. Mine would have been covered by comprehensive insurance, however, with a $2,000 deductible - I just paid out of pocket for all the effort it would have been. I did mention a concrete bolder came flying at me when an 18 wheeler bounced across the expansion joint on a bridge... Terrifying. Blew the tire out and bent the rim on the left front tire as it tore the bottom of my car out.
$2k deductible 😲
That almost makes insurance not even worth it.
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