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Electric trucks are rapidly becoming a cornerstone of the automotive landscape. And few are as eye-catching—or as massive—as the Chevrolet Silverado EV RST. But with a curb weight tipping over 8,500 lbs, this vehicle has drawn considerable attention for its sheer mass. In this team Munro teardown, we hoist the Silverado EV for an underbody inspection, identifying exactly what contributes to its hefty build. Our analysis provides a goldmine of insights for automotive engineers, EV enthusiasts, and investors interested in how design, manufacturing, and materials affect vehicle weight and performance.
Aero Optimization and Component Complexity
At the front of the Silverado EV, the team notes extensive aerodynamic shielding and active grille shutters (AGS) both on the upper and lower fascia. These elements, while critical for range optimization, introduce complexity. Multiple molded parts—including wheel spats, diverters, and aerodynamic covers—are used where other OEMs often combine these into fewer, more integrated components. This design may be driven by assembly sequencing rather than lean design principles, increasing both part count and potential assembly cost.
Another factor is the use of textured and broken-up front fascia to conceal functional elements like radar, ultrasonic sensors, and cameras. While visually cohesive and functionally effective, it comes at the cost of added material and assembly steps.
Structural Choices: Strength vs Simplicity
Underneath the Silverado EV, the cradle is a stamped, clamshell welded steel structure. This cradle hosts the steering rack, drive modules, and other major front-end components. Notably, all noise-generating elements are isolated through elastomeric mounts within the cradle rather than being hard-mounted to the body. This approach helps with NVH (noise, vibration, and harshness) control but contributes to structural weight.
Another unique feature is GM’s use of tailor-welded blanks on the front rail—a manufacturing method more commonly found mid-vehicle. These blanks allow for tailored strength through varied thickness and material grade in one sheet. Here, it coincides with the hard-mount cradle attachment, likely for joint stiffness and impact management. It’s a strategic choice, but one that adds welding complexity and mass.
Drive Module Design and Redundancy
The Silverado EV’s front drive module features a mechanical park pawl actuator, providing physical locking redundancy in addition to the electronic parking brake on the rear axle. While some EVs, like Tesla’s, have eliminated park pawls to save weight and cost, GM maintains them for added security—especially under towing conditions. In heavy-duty truck contexts, this is a necessary inclusion despite its weight penalty.
The short-long arm front suspension employs large cast components for both upper and lower control arms. These parts are significantly bulkier than equivalent pieces on vehicles like the Cybertruck or Tesla Model Y, emphasizing robustness over weight savings. The suspension is designed to support extreme weight and potential towing stresses, though this contributes to the Silverado EV’s overall mass.
Brake Package Size and Safety Requirements
While regenerative braking reduces wear on traditional brakes, it doesn’t reduce their required stopping power. The Silverado EV uses enormous brake calipers and thick bushings—highlighting the need to manage the full gross vehicle weight rating (GVWR) in emergency stops. These brakes, though rarely taxed under normal driving, must meet worst-case safety scenarios. The result? Big, heavy, overbuilt brake systems that add to the vehicle’s total weight.
Battery Pack Design and Structural Role
One of the heaviest contributors is the massive 200 kWh battery pack. Built with multiple laser-welded steel sections, this pack serves not only as an energy reservoir but also as part of the vehicle’s structure. Munro engineers describe the pack as a “structural wafer,” employing thin-gauge stamped and roll-formed steel for protective cladding. This design is functionally strong and crash-resistant but demands precision in assembly and adds significant mass.
Notably, GM uses continuous adhesives and e-coating for corrosion protection, which further adds weight. The structure is highly reminiscent of designs used by Pacific OEMs—like Mitsubishi or Honda—that prioritize scalloped steel and welded assemblies over large castings.
Rear Suspension and All-Wheel Steering Tradeoffs
Moving to the rear, the Silverado EV features steel clamshell lower control arms, contrasting with Ford’s use of large cast aluminum in the F-150 Lightning. While steel has strength and cost advantages, its stiffness-to-weight ratio isn’t as favorable as aluminum. However, complex aluminum castings also come with higher tooling and scrap costs.
Interestingly, the Silverado EV also features rear-wheel steering—a rarity among pickup trucks. This feature enhances maneuverability but requires additional actuation systems and mounting structures. Combined with steel suspension arms and heavy bushings, the rear underbody setup adds considerable weight.
Lean Design vs Legacy Truck Requirements
From a lean design perspective, Munro notes several opportunities for optimization. The use of multiple small aero parts, extra covers to protect open bolt holes, and heavy steel control arms all suggest legacy truck priorities—durability, safety, and off-road readiness—took precedence over lightweighting. In traditional ICE trucks, this approach is expected. But in an EV, each pound of extra weight requires additional battery capacity to maintain range, driving up cost.
Despite this, GM appears to be striking a balance: minimizing battery size where possible via aero enhancements, while still leaning on heavy-duty structures where performance or safety demands it. In essence, they’re accepting some weight penalties in exchange for durability and real-world practicality.
Final Takeaways: Why It’s So Heavy
The Silverado EV RST’s weight stems from a mix of conservative engineering, customer expectations, and manufacturing realities:
- Massive 200 kWh battery pack with structural integration
- High-strength cradle and rail designs with tailor-welded blanks
- Durable cast suspension components to handle heavy loads
- Oversized brake systems to manage GVWR safely
- Extensive aero shielding and underbody protection for range compensation
While it may seem counterintuitive to add weight to an EV, GM’s design decisions reflect a clear understanding of its target audience: truck buyers who demand toughness, towing capability, and no-compromise safety.
Conclusion: Heaviness with Purpose
Yes, the Silverado EV RST is heavy—but every pound is accounted for. GM’s engineers are leveraging proven ICE truck strategies and blending them with EV technologies in a way that prioritizes customer usage scenarios. While this truck may not win the lightweight crown, it stands as a formidable case study in how legacy automakers are navigating the transition to electrification.
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