Harley Copp - Ford Pinto

Ford Pinto

In 1968, Copp returned to North America to head-up Ford's crash testing program team. By this time, the manufacturer preferred large American automobiles were losing market share to smaller more fuel efficient and reliable Japanese imports. As a result, CEO of the Ford Lee Iacocca wanted a 1971 model that weighed less than 2,000 pounds and that would be priced at less than $2,000.

The first Ford Pinto was delivered in September 1970 at a retail cost of $1850, but to achieve the time scale the car had had to be designed and produced in 25 months, rather than the then usual 43 months for a new car line. Although inline with safety certification of the National Highway Traffic Safety Administration, front end testing had been completed, to save time rear-end collision testing was not undertaken until after launch, although Ford engineers knew that testing for rear-end impact was a standard safety procedure.

After rear end testing by Copp's team proved there was a problem from the bolts attaching the rear bumper to the body, and those protruding from the differential, would in an accident above 20 miles per hour (32 km/h) penetrate the gas tank, Copp issued an internal memo suggesting rectification measures.

Before final sign-off of the 1972 Pinto, in April 1971 Harold MacDonald, Ford Vice President of Car Engineering, chaired a product review meeting around a report from Ford engineers. The recommendation suggested deferring from 1974 to 1976 the incorporation into all Ford cars of either a shock absorbent "flak suit" to protect the fuel tank at a cost of $4 per car, or a nylon bladder within the tank at a cost of $5.25 to $8 per car. Agreeing the decision would allow Ford to realize a savings of $10.9 million. MacDonald agreed the reports recommendation, and hence left the Pinto exposed to rear end collisions.