Browse over 9,000 car reviews

Articles by James Stanford

James Stanford
Contributing Journalist

James Stanford is a former CarsGuide contributor via News Corp Australia. He has decades of experience as an automotive expert, and now acts as a senior automotive PR operative.

How big trucks are built
By James Stanford · 25 Sep 2015
Have you ever looked at a great big truck and wondered how they managed to build it?Putting a car together is hard enough, but truck components are so much heavier and bigger. A lot of trucks are also custom made for different customers and that means great complexity at the plant.We were lucky enough to check out the process at Iveco's factory in Dandenong.To start with, huge presses crunch steel into the shape of various components which are put to one side.Long steel chassis rails are fed through a milling machine which drills up to 200 holes per beam for all the bolts and lines, while a plasma cutter is used to slice them to the right lengths.The amount of hoses and lines is incredibleWorkers then attach other chassis members, sub-frames and the engine mounts. At this stage the chassis is upside down. This way, the large and heavy axles can be dropped down on to the chassis, which is sitting on a mobile platform riding on small rails that protrude from the factory floor. An overhead crane does the heavy lifting.The chassis is then sent through a booth to be spray painted by two workers who look like they are wearing bio-suits, which have in-built oxygen lines.Now it's time for all the electrical lines and air hoses to be fitted. The amount of hoses and lines is incredible.Hats off to the workers for not getting any mixed up.The wheels are then fitted and the chassis is flipped over on to its correct side and the engine and transmission are fitted.Iveco imports engines from two sources, its own company in Europe and Cummins, which supplies a range of engines including the 15-litre six-cylinder for use in Iveco's largest truck, the Powerstar.The engines come fully assembled and are placed on trolleys before they are lifted into position with an overhead crane system.Back in the 1970s and 80s, when Iveco built trucks with petrol engines, workers would also have the job of tuning the carburettors on the line (could you imagine the noise?). These days, the super complex injection systems are preset and workers only need to put the engines on the dyno to check for faults.On the other side of the factory, which started out as an International truck plant in 1972, workers are assembling the cabs. A few are imported complete from Europe, but most are made at the factory.The components are quality checked after being stamped. To guard against rust, all the components are dipped in a pool of special primer paint. An electric charge is run through the liquid, which attracts the paint to all the metal surfaces, including the hard to get at nooks and crannies.All the components are then welded together by hand. There is limited automation here, and some parts are bolted on.After about 10 days on the line, the truck is ready to start workThen the cabin is then painted, baked at 140 degrees and lightly buffed before getting another coat.Workers then inspect it under a bank of UV lights for any imperfections. It is then carefully lowered onto the chassis and really does resemble a proper truck for the first time.The dashboard is then fitted with instrument clusters dropped in and all the wiring, cables and tubes are then connected. The steering wheel, carpet and seats are next.The trucks are then run over a pit and all the fluids are checked before they go through series of tests, including a short drive out on the road to make sure everything is just right. Finally, after about 10 days on the line, the truck is ready to start work.
Read the article
Monster Jam trucks have monster appeal
By James Stanford · 18 Sep 2015
There is something about monster trucks that captivates young kids, especially boys.
Read the article
Ford Ranger and Territory 2015 review
By James Stanford · 18 Sep 2015
James Stanford road tests and reviews the Ford Ranger and Territory with specs, fuel consumption and verdict.
Read the article
HSV GTS vs Mercedes C63 AMG S
By James Stanford · 04 Sep 2015
Think of them as family sedans that double as muscle cars. James Stanford rates the V8s.
Read the article
2015 Ford Ranger XL and XLS miss out on update highlights
By James Stanford · 28 Aug 2015
Tradies might feel a bit miffed when they sort through the detail of the new Ford Ranger line-up.
Read the article
Which is the right colour to choose for my new car?
By James Stanford · 28 Aug 2015
Metallic finishes and "premium" paints mean owners can stand out - at a cost.
Read the article
2015 Mercedes-Benz Vito | new car sales price
By James Stanford · 14 Aug 2015
The Benz van has refined engines, ample space — and, as extra-cost options, safety kit galore.
Read the article
Mercedes-Benz Valente 2015 review
By James Stanford · 07 Aug 2015
James Stanford road tests and reviews the Mercedes-Benz Valente with specs, fuel consumption and verdict.
Read the article
2015 VW Transporter detailed
By James Stanford · 25 Jul 2015
The sixth generation of the Volkswagen Transporter arrives in Australia in November with a range of upgrades aimed at making life easier for owners and operators.
Read the article
Honda HR-V VTi 2015 review
By James Stanford · 17 Jul 2015
James Stanford road tests and reviews the Honda HR-V VTi with specs, fuel consumption and verdict.
Read the article