In this episode of Munro Live, Sandy goes into great detail about our recent teardown of the Ford Mach-E Rear electric motor.
Well, this motor isn’t exactly what Sandy expected to find in this vehicle. The part Sandy was the most impressed with was the magnets themselves, but from there is seems to be a series of pointers for improvements. From excessive laminations, buried pumps and filters, and the largest motor casing we have ever seen, there is a lot of surprises.
In general, this motor has a lot of parts and processes involved in its manufacturing and assembly, and although it has come up in other videos and popular quotes that electric vehicles have fewer parts than ICE vehicles, especially comparing engines to electric motors, but this video proves, that is not always the case.
When comparing this electric motor to Tesla’s and VW there are many points of improvement that are possible from a complexity reduction standpoint, with Sandy giving a special shout out of praise to the design of VW ID.4 motor that removes the need for an oil pump by creating an innovative component that solves this problem.
In general, this is a concise and very interesting episode that will tell you all you need to know about the Mustang Mach-E rear motor as well as providing many moments of Sandy’s subtle humor and his lifetime of design experience.
Is there a revolutionary cooling design in the Ford Mach-E? This episode starts off with Sandy bringing up this very topic, saying that they have found something unique inside this design.
Sandy hands over the reins to Ben as he explains what is found in each battery bay, focusing on the cooling plates and their unique design using a dimpled design pathway for the coolant to flow, similar to the “Plinko Board” from “The Price Is Right” causing the coolant to move in random directions around different areas of the plates and creates a turbulent flow that more effectively transfers heat. All of the coolant is supplied through well designed cooling lines that are attached through quick connects.
Ben also points out that it is actually the battery modules that fix the cooling plates down using the studs that protrude through the cooling plates, which is a great double use of a fastener.
Sandy and Ben then move over to look at the battery modules and cells themselves and where we get a chance to see that the Ford Mach-E and Chevy Bolt batteries are identical which makes sense as they are both supplied by LG. However, Ford made some interested improvements on the rest of the modules, using collector plates that are copper that have been nickel plated with the ends of the battery tabs welded to the plates, but more importantly, Ford chose a smart ribbon cable design for the circuitry to manage the battery cells which prevents breakage during installation and ultimately a cost savings.
From there Ben goes over a great design choice on the Ford Mach-E where Ford has placed bent aluminum strips that aligns up witht the thermal interface compound allowing them to use less compound, saving money, and helping to speed heat transfer. Ben also talks about the foam pads in between the cells which allows for expansion as the cells age.
Finally, Sandy talks about our future “best-of-best” battery tray design that we are coming up with. To catch what he says, watch the full episode below:
Sandy and Ben Analyze the Rear Interior of the Mach-E
In this episode, Sandy and Ben remove the back seat of the Mach-E and have a look through the rear interior.
Sandy points out some interesting finds when taking apart some of the rear gate interior trim to see what is beneath. Find out what happens when the interior designers and the sheet metal body designers don’t get along and why brackets are a crutch.
Sandy goes on to explain why he likes the hatch alignment feature in the rear clasp holding the hatch closed as well as several other interesting points including NVH and interior fitting solutions. But for the full info, you gotta watch. Click below:
In this episode of the Ford Mustang Mach-E teardown, Sandy and Ben have a look at the door module assemblies and point out a bunch of their findings that they like.
SPOILER ALERT! Ford seems to have a more Lean Design with a lower cost and weight than compared to the Telsa! Another interesting point is Sandy unearths two very ancient reports (going all the way back to 1985 and 1983 respectively) where he suggests using snap-fits to put the door together.
However, to see all of the goodies we found in this door, you have to watch the video below:
In this dramatic episode of Munro Live, feel the fear of Sandy as he is shocked with what he finds in the Ford Mach-E Thermal System. After a brief faint and being revived by the Octovalve, Sandy uncovers a winding snake pit mess of hoses and pumps that we are sure to confuse mechanic and assembly worker alike. Most likely in an attempt to save money by using off the shelf parts, this is by far one of the worst cooling designs we have seen at Munro.
This video attempts to describe the complex path that this cooling system takes. Warning this video is not for the faint of heart. To watch it in all it’s hilarity, click below:
Well, here we are at episode 4 of the 2021 Ford Mustang Mach-E Review and all we can say is wow! Sandy and the team are not easily impressed, but the Mustang Mach-E is definitely an impressive car. Sandy even exclaims that, “From a suspension standpoint: If I gave Tesla an A, this would get an A+, and the reason for that is because they are so simple and so inexpensive, and they’re doing the job!”
From the hallow cast cradles to a mysterious reservoir and something Sandy is calling the T-Rex bar, there are lot’s of interesting finds under this car, including the fact that Ford has made this battery very easy to drop out and change – great for serviceability but also allows for battery quick change is that business model pans out in the future.
But to get the full details you have to watch the show:
Sandy Takes A Look Under The Hood of the 2021 Mustang Mach-E
In this second installment of the Mustang Mach-E series, Sandy has a look at what is under the hood of the Mustang Mach-E. Now if you have watched our last episode, then technically you know that Sandy has already looked under this hood, but upon further inspection, Sandy finds two secrets that make him propel this vehicle into a position of competition with the Tesla.
Beyond this, Sandy talks more about the frunk, what is under certain access panels including the 12 Volt battery, seals, coolant fill, etc. To watch the full episode and find out what has Sandy so enamored with the Mach-E, you will just have to watch the video below:
In this first episode of Munro Live’s next car review, that being the 2021 Ford Mustang Mach-E, Sandy gives his first visual impressions of the car, stating that it reminds him of a Japanese design or look. Sandy likes the overall look of the car and including the lenses, but isn’t a huge fan of the wheels; he still preferred the look of the ID.4’s wheels better.
From the gaps and fit, finish, and quality perspective, everything was done perfectly. The lack of door handles is also a design choice that Sandy loves and the general sleekness of the car. Sandy makes mention of the Shingling designed into the hood to avoid problems with matching both sides where they overhang a little on the front light lenses; it also adds a certain esthetic that Sandy is into. Sandy’s impression of the front of the car, in general, is very positive and he likes the design choices from the faux grill to the Mustang logo.
Starting at the driver-side door of the vehicle, Sandy makes mention of the locking mechanism on the door, a Ford born esthetic. Once inside, besides the car being dirty, Sandy is enamored with the tambour doors on the console and the fact that the cupholder unit has space underneath for a purse or a tissue box – perfect for his wife.
Sandy goes on to reveal more aspects of the car he likes and little secrets, especially the fact that he can operate the Mustang infotainment GUI to easily find the map function with charging stations laid out (unlike the VW ID.4), but to find all of the Easter eggs, you will just have to watch by clicking below: