Jump to content

Tight-ass manufacturer short cuts and cost saves


grogee
 Share

Recommended Posts

What are your favourite manufacturer cost-saves? I'll start the ball rolling with MK1 Panda grille, mounted one way round for air cooled and t'other way up for posh water cooled models. 

Then there's Skoda using a hatchback bootlid on their estates so they don't have to tool up for a separate version. 

download.jpeg

P1080030-lead.jpg

Skoda_Favorit_136_L_back.jpg

2560px-1996_Skoda_Favorit_Forman_GLX_Estate_(11320735503).jpg

Link to comment
Share on other sites

Garrett (Honeywell engine boosting) 

Rather than drill 2 holes, Mark an aluminium plate, and rivet it to the compressor housing they (we) decided to Percusion Mark the aluminium housing saving £0.17956765498765 per turbo. 

Rather than machine a flat on the housing for washers to sit flat on, they used bolts that had a shoulder which eas serated that cut its own flat.  Saving the cost of machining, and the cost of a washer x 8. Oh no wait. They decided to have slightly bigger bolts  and drill 2 less holes.  Total saving per turbo £1.2345239865

Lucas.  Smart stop start solenoid. Rather than have the plunger during in a brass tube with an o ring at either end (On the outside diameter of it) and a brass washer at the end, (to stop the plunger sticking due to magnetic attraction) replaced with a brass flat ended bullet and one seal. Saving £0.48 per DPC pump x 1 million a year x 7 year product life. 

Link to comment
Share on other sites

39 minutes ago, grogee said:

Then there's Skoda using a hatchback bootlid on their estates so they don't have to tool up for a separate version.

Skoda_Favorit_136_L_back.jpg

2560px-1996_Skoda_Favorit_Forman_GLX_Estate_(11320735503).jpg

Its even worse then that, if you pull the carpet up on the estate you can see where the estate "extension" is welded onto the hatch body. At least there was on mine! 

What about the volvo 200 estate using saloon doors so only one set of doors would need to be made. It's the same on the 700 and 900 series but the 200 looks odd due to the doors having the odd saloon shape up top. 

Link to comment
Share on other sites

Peugeot 309 & 205 using the same doors (took me years to spot that despite owning a 309 😀)

Ford were good at this too, mk1 & mk2 escort estates had the same panels from the front wings back. 

Also Land-rover Discovery - the first ones had sherpa (freight rover) headlights, Maestro van rear lights and Marina door handles

Link to comment
Share on other sites

Cult classic, not best seller – The Morris Marina | Car & Classic Magazine

Morris Marina Coupe: they didn't want to make special doors for it so used the front doors from the saloon.  The coupes were three inches shorter than the saloon, overall, but had the same wheelbase so the proportions were odd.  It's effectively a two door four door, aesthetically speaking, like some old fashioned kustoms with welded up rear doors.  

Morris.marina.arp.750pix.jpg

The saloon looked like this.  I'd wager that with a little bit of bodywork alteration it would be possible to fit saloon rear doors to a coupe, creating a four door variant.  The gap between the rear wheelarch and back of the front door looks very similar on both types.  

Link to comment
Share on other sites

The MK1/2 escort van was the same from doors back too it also used 105E Anglia rear doors & rear 1/4 bumpers (the MK2 van had square frt bumpers as per car).

The MK3/4/5 cortina EST used the same shell (only the rear doors/ wings, scuttle panel ,frt valance panels,slam panel differed on the mk3).

Same for MK1/2 Granada EST.

Link to comment
Share on other sites

Left hand drive wiper mechanisms..

Renault & Peugeot being the prime culprits (MK2 Clio, MK2 Grand Scenic, 206 etc) 

Instead of engineering a RHD mechanism like most other manufacturers, they just add in another linkage to the offside arm to increase the sweep

Despite how irrational it is, it irritates me every time I see one - it's like they thought "oh shit, we forgot to make a RHD model, quickly think of as many things we can leave as they are" 

See also - bonnet releases on our passenger side...

Link to comment
Share on other sites

6 minutes ago, RoverFolkUs said:

Left hand drive wiper mechanisms..

Renault & Peugeot being the prime culprits (MK2 Clio, MK2 Grand Scenic, 206 etc) 

Instead of engineering a RHD mechanism like most other manufacturers, they just add in another linkage to the offside arm to increase the sweep

Despite how irrational it is, it irritates me every time I see one - it's like they thought "oh shit, we forgot to make a RHD model, quickly think of as many things we can leave as they are" 

See also - bonnet releases on our passenger side...

@dollywobbler ^
 

Rover 45- later models have the passenger front windows lift on the transmission tunnel only - so it doubles as the main passenger switch and in lieu of extra componenty on  the driver’s door. Clever but stingy.

Link to comment
Share on other sites

There seem to be a number of Ford lickers on here so thought I'd ask.

Mk1 Onions had a stubby tailpipe as standard. It was much shorter than the equivalent on the mk3 Escort and tucked quite far in contrast. Father Longbridge replaced his C plate Onion with an E plate Ghia equivalent with a mild facelift. From what I remember, the tailpipe had a short extension piece bolted onto the end from new so it appeared someone in Ford decided to do a cheap fix*. 

Can anyone confirm this? I'm assuming the exhaust was sourced from the Escort and then bodged onto its booted brother to save Ford's design team a few £££ ...

As an aside, Orions have aged very well, haven't they?

Screenshot_20220511-214522_Chrome.jpg

Escort-Mk3-Ghia-r34_trans_NvBQzQNjv4BqTQRVpoYOXfb6kXamLFSPBBZGdkx_qC1PGsMDn_VuevY.webp

Link to comment
Share on other sites

7 minutes ago, Crusty Sills said:

This has always annoyed me.

VAG (various models) on a facelift, moved the side indicators from the wing to the wing mirror.

Adding a stupid little fucking badge in the oval indicator recess!!! 

Also see Ford Focus MK2 face lift for the same 

 

IMG_20220511_213723.jpg

IMG_20220511_213739.jpg

Mercedes of a similar era did this but then also revised the tooling to avoid having the redundant hole. So very thorough- except they then did a short cut and time save on the rust prevention instead.

 

 

Link to comment
Share on other sites

Sometimes these little short cuts are beneficial- some manufacturers supply a fairly standard loom to most models so lower spec models are often plug and play with DIY bolt on extras - eg elec/ heated seats.

Link to comment
Share on other sites

6 minutes ago, Dick Longbridge said:

There seem to be a number of Ford lickers on here so thought I'd ask.

Mk1 Onions had a stubby tailpipe as standard. It was much shorter than the equivalent on the mk3 Escort and tucked quite far in contrast. Father Longbridge replaced his C plate Onion with an E plate Ghia equivalent with a mild facelift. From what I remember, the tailpipe had a short extension piece bolted onto the end from new so it appeared someone in Ford decided to do a cheap fix*. 

Can anyone confirm this? I'm assuming the exhaust was sourced from the Escort and then bodged onto its booted brother...

As an aside, Orions have aged very well, haven't they?

Screenshot_20220511-214522_Chrome.jpg

Escort-Mk3-Ghia-r34_trans_NvBQzQNjv4BqTQRVpoYOXfb6kXamLFSPBBZGdkx_qC1PGsMDn_VuevY.webp

I had a G reg Orion at one point and don't remember there being anything odd about the exhaust pipe, other than the amount of blue smoke that used to come out of it of course!  Perhaps your one was just an oddity.

Link to comment
Share on other sites

4 minutes ago, Missy Charm said:

I had a G reg Orion at one point and don't remember there being anything odd about the exhaust pipe, other than the amount of blue smoke that used to come out of it of course!  Perhaps your one was just an oddity.

Nope. Standard setup on them as per photos. 

Link to comment
Share on other sites

Pug 107 and its variants was a fantastic example of penny pinching...though I don't really feel it's fair to call it that as it wasn't a car that was made cheaply, rather it was a car that was designed to be cheap to make.

[] Instrument pod attached to the steering column rather than dash, minimising the amount of mouldings differing for LHD/RHD cars.

[] Identical ns/os seats.

[] Power window switch on the respective doors only.

[] Interior light switch on the driver's door only (that DID feel like penny pinching).

[] "Frameless" bootlid ala Citroen AX.  Albeit less prone to spontaneously shattering I believe.

Sure there were a dozen other things they'd done to simplify construction too but I can't remember them all now.  Despite that though it never felt cheap or flimsy, and when you realise when it was launched it still was a clever bit of packaging.  Only really started to show its age when VW came out with the Up and started to shove big-car luxury toys into shopping trolleys.

Link to comment
Share on other sites

5 minutes ago, Leyland Worldmaster said:

Also, car manufacturers that use nice feeling plastics, etc in the front of the car, and harder; less nice feeling materials in the back... 

Noticed this with VW Golf, Audi A3 and some Ford Focuses... 

VW do that with the accent lighting in a load of models too - runs all the way across the dash and along both front doors - nothing in the back though!  That just feels so obviously stingy.

Link to comment
Share on other sites

4 minutes ago, Missy Charm said:

I'm still not sure what you mean.  Mine looked like this:

SE England - g reg *mint* ford orion | Reptile Forums

Except in white.

Yes, yours was a facelift, same as my father's E plate Ghia.

I mentioned in my post that the facelift cars had a sleeved extension bolted over the end of the tailpipe to make the exhaust longer. I think you're missing the entire point I'm stating about the pre-facelift Orions which didn't have this...

Link to comment
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
 Share

×
×
  • Create New...