Panel Gap and Build Quality

[buster]

Like with many engineering design decisions, there is a point of which it takes exponential cost/effort to achieve minor incremental gains. While panel gaps may be a indication of quality in other areas (eg. if an OEM was attentive to panel gaps, it's likely they've put similar effort to other areas), it doesn't really offer that much value past a certain point.

Other than visual, the only direct and meaningful impact is wind noise. But that can be mitigated with a rubber seal which is cheaper and works better than trying to achieve a 1mm gap. Interestingly, on my 2024 Outlander I noticed they used a rubber seal around the front door panel gap to minimize noise but not on the rear doors (to save cost). I personally would prefer a vehicle with a 3mm gap that's filled with a rubber than an open 1mm gap that looks good from afar.

I was thinking about that. I have some pretty big panel gaps on the Colorado, mostly hood, but I'm not sure it has much of an impact on anything. Surely doesn't impact the drivetrain so....

 

[Carmudgeon]

It's more than just the gaps.

The alignment of the trim, light fixtures, and other elements that the designers make part of the character lines also stick out like a sore thumb when not built properly.

Sometimes, the work is so shoddy, it's hard not to spot. The Mercedes MLs that came out of the then new Alabama plant were easy to spot with their poor tailgate fits in traffic. Teslas, in general, and the problematic falcon doors. I've seen a brand new Grand Wagoneer where the misaligned rear lights betrayed the poor build.

IIRC, someone posted a picture here in the past of a new Lincoln with a badge mismatch or some other glaring flaw that not only left the factory, but made it through distribution, PDI, and didn't need a trained eye to spot.