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Front bumper paint mismatch on ordered car, what should I do?

EvilMerlin

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It is very plain that is a shadow. You may have missed that having many fog and cloudy days, living across the pond.

You're excused....
Found the dick of the group...

The guy is worried about his new car and you give him shit.

Dick move, yank.
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motodad

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There's not anyone in this forum that lives around the Morgan Hill, CA arear right?
I can probably get someone to go look at it.

I moved away from there 2 years ago to SoCal. Is it at The Ford Store Morgan Hill? I have bought 4 vehicles from them. One of my closest friend's lives in Mo Hill and I can send him over to look. (If he is home from Shasta). He is a car aficionado and was with me when I bought my F250 and Mustang from TFSMH. He is my paint/detail advice guy and the reason I bought a supercharger the day after I bought my mustang. Let me know.

Oh and if he is not available, my old business partner also is in Mo Hill and retired so he has a lot of time on his hands.
 

Elp_jc

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At least in California here dealers are supposed to disclose repaired damage on a form I signed. I doubt they would lie on that otherwise it's a criminal matter if I discover anything, and they certainly wouldn't give me a different story then if I asked.
Many times the cars are repaired at the port, so dealers are off the hook. Just ask man; tell them to investigate, and report back to you. If the answer is NO, then I'd definitely believe them. That's what I did when I bought a new Porsche in Cali 4 years ago (also sight unseen). By the way, since you're going to wrap the car with PPF, it's going to be less noticeable, so not a huge deal if it wasn't repainted. Good luck.
 

ORRadtech

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It was my original plan to drive up in my trade in, do the whole in person thing, have a nice drive back on highway 1, etc. I was even going to spend the weekend and have it PPF wrapped before bringing it back down, but the guy said that's a bad idea since he recommends coming back in a week for touch ups etc, so I should only do that work locally. That in addition to my partner being worried about COVID stuff etc, I settled on shipping as a better option. I'd rather have it shipped down here straight to my Xpel guy rather than driving my like-new trade in 400 miles on a god awful trucking-route interstate up there, and a new car 400 miles back unprotected. It wasn't until after I had decided that and booked a carrier that I even found out about paint issues =as something new cars can even have, it never occurred to me honestly. My current car I bought last year is the only new car I've ever had. Like I've said this car is a keeper for me, I want my kids to be able to experience it someday, I'm not worried about resale. So if there's problems with it I can't live with when I get it I don't mind fixing them properly using a shop that will do a better job than the dealer would anyway.
Everyone's situation is different. You do what works for you.
I'm just saying that if I'd have waited as long as you say you have my ass would already be in the drivers seat.

As for COVID, a lot of people are frightened and/or use it as an excuse.
I've worked in a major Atlanta hospital since day 1 and have not contracted it. Plus, I've traveled (flown to Phoenix and Orlando) and went to a casino this year with no issues.
Do a few things and you reduce your chances of getting it tremendously. 1, only deal with people you don't live with who are wearing a mask. 2, wear a mask yourself. 3, be meticulous about hand hygiene. 4, use common sense about being in groups of people, the fewer you have to be close to the better.
The disease is definatly out there but as long as you're careful there's no need to put life on hold.
 

GrabberBlue5.0

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I was a paint process engineer for a Ford plant about 1.5 years ago and I directly handled several paint related warranty claims. Let me just say, if it is as bad as the photos looks, it is ABSOLUTELY a warrantable claim. You can never expect 100% match between two different substrates being painted in two different places, but that's more than a half shade difference. I would call it 3-4 shades difference. That bumpers looks too blue.

I saw a response about the mating angle of the fascia and the hood, but the mating angle of the two panels is essentially zero. We had a ton of issues with paint flop on metallic paint for the 2018 navigators because the front fascia and the front quarter panels had a different mating angle (about 30 degrees) than with the fascia/grille mating angle (roughly 0 degrees). Long story short we could never get the two to match due to the metallic flop and we basically had to have those panels redesigned for 2020.

My point is, IF the paint is as bad as the photos look, file a warranty claim. A good dealer will give you zero push back.
 

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Rusherific

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Everyone's situation is different. You do what works for you.
I'm just saying that if I'd have waited as long as you say you have my ass would already be in the drivers seat.

As for COVID, a lot of people are frightened and/or use it as an excuse.
I've worked in a major Atlanta hospital since day 1 and have not contracted it. Plus, I've traveled (flown to Phoenix and Orlando) and went to a casino this year with no issues.
Do a few things and you reduce your chances of getting it tremendously. 1, only deal with people you don't live with who are wearing a mask. 2, wear a mask yourself. 3, be meticulous about hand hygiene. 4, use common sense about being in groups of people, the fewer you have to be close to the better.
The disease is definatly out there but as long as you're careful there's no need to put life on hold.
My life is not "on hold," but thanks. Like I said the COVID aspect was more an issue for my partner than myself, personally I don't see the point in worrying as long as you're taking the standard precautions like you listed. But we also know two acquaintances our age (mid 30's) and otherwise healthy who have gotten it and 1 had a stroke, the other heart failure and is dead, so I'm happy to respect her own wishes regarding it. But this isn't the topic at hand and doesn't matter.

Luckily through the power of the internet I actually have someone from this forum helping me with getting eyes on it today! So that will be a big help and I'm glad I posted here! Shoutout to Motodad...
 
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Rusherific

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I was a paint process engineer for a Ford plant about 1.5 years ago and I directly handled several paint related warranty claims. Let me just say, if it is as bad as the photos looks, it is ABSOLUTELY a warrantable claim. You can never expect 100% match between two different substrates being painted in two different places, but that's more than a half shade difference. I would call it 3-4 shades difference. That bumpers looks too blue.

I saw a response about the mating angle of the fascia and the hood, but the mating angle of the two panels is essentially zero. We had a ton of issues with paint flop on metallic paint for the 2018 navigators because the front fascia and the front quarter panels had a different mating angle (about 30 degrees) than with the fascia/grille mating angle (roughly 0 degrees). Long story short we could never get the two to match due to the metallic flop and we basically had to have those panels redesigned for 2020.

My point is, IF the paint is as bad as the photos look, file a warranty claim. A good dealer will give you zero push back.
Thanks so much! This is exactly the kind of help I was looking for and fascinating insight. I can see how two panels meeting at an angle would throw people off. Funny story I actually did some of the graphics for the Aviator ICE. I don't know if any of that wound up in the Navigator as well.

We'll see what my guy says about the car when he sees it. But it's nice to know this is something Ford does recognize if it turns out to be an issue.
 

GrabberBlue5.0

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Thanks so much! This is exactly the kind of help I was looking for and fascinating insight. I can see how two panels meeting at an angle would throw people off. Funny story I actually did some of the graphics for the Aviator ICE. I don't know if any of that wound up in the Navigator as well.

We'll see what my guy says about the car when he sees it. But it's nice to know this is something Ford does recognize if it turns out to be an issue.
It's so odd to me because I can't understand the disconnect with respect to warranty claims. Some times it's the dealer (I believe just being lazy) denying the claim without actually submitting it to FOMOCO and other times we had to cover BS warranty claims. The two worst issues I ever had to deal with (both worst by ridiculousness and cost) was 1) we had to pay to have a dealer repaint an entire expedition that had been egged (not just one or two panels), and 2) we had to pay for a dealer to repaint an expedition that came from the factory looking terrible (it genuinely was our fault and I'll admit that every time I'm asked), BUT the dealer then sold it at auction to another dealer that submitted a 2nd warranty claim for the same vehicle. It turns out the first dealer did such a HORRIBLE job of repainting it the vehicle looked even worse and a second dealer got us to repay to re-repaint the same vehicle.

Generally the engineers within FOMOCO are very decisive and will not turn down a true warranty claim (an ACTUAL factory paint defect). It's all the other politics (at least from what I saw) between the dealers not wanting to submit claims and the bean counters at Ford trying to save money and deny a warranty claim on a technicality, that put a bad taste in people's mouth when dealing with Ford warranty claims.

As far as engine graphics, I never got to see much of that simply because the vehicles were painted long before a powertrain was installed. I love the inner working of the automotive industry, but because it is a 24/7/365 operation, management often expects you to be working if the line is running and a lot of people get burnt out very quickly. I lasted 4 years and loved every second of it, but the problem was I barely even knew my son until he was 2.5 years old, and I almost lost my wife over it as well.
 

Idaho2018GTPremium

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I was a paint process engineer for a Ford plant about 1.5 years ago and I directly handled several paint related warranty claims. Let me just say, if it is as bad as the photos looks, it is ABSOLUTELY a warrantable claim. You can never expect 100% match between two different substrates being painted in two different places, but that's more than a half shade difference. I would call it 3-4 shades difference. That bumpers looks too blue.

I saw a response about the mating angle of the fascia and the hood, but the mating angle of the two panels is essentially zero. We had a ton of issues with paint flop on metallic paint for the 2018 navigators because the front fascia and the front quarter panels had a different mating angle (about 30 degrees) than with the fascia/grille mating angle (roughly 0 degrees). Long story short we could never get the two to match due to the metallic flop and we basically had to have those panels redesigned for 2020.

My point is, IF the paint is as bad as the photos look, file a warranty claim. A good dealer will give you zero push back.
I'm a mechanical engineer and interested in this. I understand paint flop, but can't tell exactly where the problem areas are by just looking at a photo of the Navigator. Is it at the seam, the angle from the light down to the wheel well? I looked at a 2018 Navigator and a 2020 Navigator side by side (below) and couldn't really tell an obvious difference between the front fascias except for some minor linework changes above the lower grille.

2018:
Navigator 2018.webp



2020:
5270ace8-2020-lincoln-navigator-1.jpg
 

GrabberBlue5.0

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upload_2020-7-22_13-35-54.webp


So in the blue circled area, the mating angle was basically zero, and in the red circled area, the mating angle was something like 10-13 degrees (or maybe even less, I misspoke earlier when I said 30, it's been a while since I dealt with this and I am having a hard time remembering all of the exact details). The panels were designed to be flush with one another but with the front fascia, having been injection molded plastic, had something happen in the fascia/fender mating area that made the fascia "flare out", in the area in which it was to mate with the quarter panel. the result was a relatively large mating angle which was simply a byproduct of the fascia molding process. If I remember correctly the internal specification for mating angles is something like <6 degrees. This is really only an issue with metallic paints, because solid colors do not "flop" like metallic colors do.

The redesign of the fascia for 2020 is very subtle but appears to require a new, or at least reworked mold. It's likely that area was reworked to prevent the "flaring out" of the fascia. I was no longer with Ford by the time the 2020 rolled around so I do not know all of the details behind it.
 

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Rusherific

Rusherific

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I'm a mechanical engineer and interested in this. I understand paint flop, but can't tell exactly where the problem areas are by just looking at a photo of the Navigator. Is it at the seam, the angle from the light down to the wheel well? I looked at a 2018 Navigator and a 2020 Navigator side by side (below) and couldn't really tell an obvious difference between the front fascias except for some minor linework changes above the lower grille.
I found a couple photos with more metallic style paint that might be showing the issue he's talking about, you can see a sudden brightness change here at the wheel well seam. They originally must not have met at a flush angle for some reason, which does indeed seem like an odd choice for that area of bodywork. The paint color is correct but the specular highlight is being interrupted basically by the sudden change in reflection angle.

...I feel like I'm cursed now, I see issues everywhere now, every other photo and car I see on the street I notice mismatching panels now. I noticed it last night in very nice photos of a mustang in 2020's grabber lime! it's like the world's worst superpower :angry:


front-quarter.jpg

2018-Lincoln-Navigator-3.jpg
 

GrabberBlue5.0

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I found a couple photos with more metallic style paint that might be showing the issue he's talking about, you can see a sudden brightness change here at the wheel well seam. They originally must not have met at a flush angle for some reason, which does indeed seem like an odd choice for that area of bodywork:

...I feel like I'm cursed now, I see issues everywhere now, every other photo and car I see on the street I notice mismatching panels now. I noticed it last night in very nice photos of a mustang in 2020's grabber lime! it's like the world's worst superpower :angry:
Yep, that's exactly this issue to which I was referring. Some colors did it much worse than others. All of us in the paint shop would cringe when we saw that, especially when Venus Williams got hers as one of the first few deliveries and showed it off. I think it was on a website or magazine or something. That particular color did it the worse... Chroma Crystal Blue. You think you have it bad... imagine being the engineer that has the responsibility of dealing with warranty claims, fixing processes to prevent the warranty claims, and also being in charge of the automation that paints these bad boys lol. I see EVERYTHING. There's no such thing as a perfect paint job.

upload_2020-7-22_13-48-9.webp


To make matters worse, that particular color was only available on Black Label trims which were a minimum of like $100k
 
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Rusherific

Rusherific

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That's amazing. I guess my question is how does this get past both the design/prototyping phase and also the QA for each car built subsequently? Like did no one notice the Navigator issue until they were being sold, or was it too late in the process to do anything about it/the bean counters didn't care? And then, for all cars from any given manufacturer, which seem come off the line with badly matched panels often enough...are the standards that low or is it hard to judge until the cars sitting out in the sun on a lot? Just curious.
 

GrabberBlue5.0

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Well, I believe honestly there are just so many things going wrong when you have a new build that it slips through the cracks. Yea that defect is obvious now, but it doesn't even show up on the radar when you're dealing with the plethora of issues coming your way, like having to sand e-coating off of entire panels due defects in the incoming metal bodies, or you just literally ran a robot through the last 7 liftgates that just came through the paint booth,or the ASRS is dropping/knocking painted bodies 70 feet to the ground. That's what makes automotive so frustrating/stressful but also incredibly rewarding.

People (generally, not anyone specifically unless you are a perpetual whiner) think building a car is an easy job and there shouldn't be a single issue with a brand new car coming off of the assembly line. But if you step back and look at it, it's actually pretty amazing we build anything at all in a given day, much less have 1600 units per day (between EXP/NAV/Super Duty) rolling off of the end of the assembly line.

Eventually all of those issues get worked through, but it's always a learning process. And you gotta repeat that process every time there is a moderate to major vehicle redesign or a plant re-tooling.
 

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upload_2020-7-22_13-35-54.webp


So in the blue circled area, the mating angle was basically zero, and in the red circled area, the mating angle was something like 10-13 degrees (or maybe even less, I misspoke earlier when I said 30, it's been a while since I dealt with this and I am having a hard time remembering all of the exact details). The panels were designed to be flush with one another but with the front fascia, having been injection molded plastic, had something happen in the fascia/fender mating area that made the fascia "flare out", in the area in which it was to mate with the quarter panel. the result was a relatively large mating angle which was simply a byproduct of the fascia molding process. If I remember correctly the internal specification for mating angles is something like <6 degrees. This is really only an issue with metallic paints, because solid colors do not "flop" like metallic colors do.

The redesign of the fascia for 2020 is very subtle but appears to require a new, or at least reworked mold. It's likely that area was reworked to prevent the "flaring out" of the fascia. I was no longer with Ford by the time the 2020 rolled around so I do not know all of the details behind it.
Ah OK, I was wondering if those were the areas, but I didn't see a 30 deg difference at the fender to fascia interconnect. Makes sense now. Thanks for the explanation.
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