Received this report of an extrication challenge from a southern Florida fire officer. This is just the beginning I'm afraid.

Report:
We attempted to cut the A-post on a 2007 VW Jetta with our Holmatro 3020-UL C-cutter, but were unable to get through on the first attempt. It took three tries to get through the A-post, but the B-post was impossible to cut with our hydraulic cutters. Apparently, Volkswagen has installed a creased sheet metal roll bar in the center of the roof on this model, that runs through both B-posts, and across the top of the roof. The A-posts and C-posts are similarly reinforced, but we were able to cut through both with considerable difficulty.

I would like to know if you have any helpful information on what makes and models are using this new design, and how we can approach it in an extrication. Fortunately, we accomplished this extrication by just cutting sheet metal, and flapping the roof back. Your input is much appreciated.

My Reply:

You're sort of at the cutting edge of this new problem and I do not have a lot of information out on it yet. The exotic metals we speak about such as Boron, are becoming more popular with the 07 models because the government changed the side impact standard, effective with the 07 model year. So what you guys ran into is going to become a more and more frequent occurrence.

Automakers have reached a point of no return with side impact airbags, Seats, doors, and roof is just about all they can do from the airbag perspective. But the new government standard pushes them further. So with airbag technology maxed out, they have turned to a beefed-up side structure as the solution to meet the Standard. That's why we'll see more and more stronger, cut-resistant B-pillars for example.

Subaru started on this impact standard mission back with their 2003 models. I cut a 2003 Forester B-pillar with a rotary saw just to see what it was made of. It was 7 layers of steel with an actual rebar rod welded inside the core of the pillar. That was 2003!

Subaru claims that the GD chassis is 148 percent and 82 percent stiffer in torsional and beam rigidity, respectively, than the GC chassis. This stiffness is primarily due to the addition of a steel "ring" which encircles the cabin at the B-pillar. While the stiffness was increased for passenger safety, it has the added benefit of providing more stability for motorsports events.

In terms of safety, the GD chassis scored much higher than the GC chassis and earned a "Good" rating (highest mark) from the IIHS's offset crash test. 4 stars front driver, 5 star front passenger and 4 star side safety ratings from the NHTSA. In a magazine article from the Dec. 2005 Firehouse magazine (a periodical written and made for firefighters), Ron Moore writes how it is well-known that the Impreza chassis has great protection in its B-pillars. This side structure has 8 layers of high-strength, high-tension steel including a round steel bar running through the middle. The author notes how drivers simply walk away from horrific side-impact accidents.