Fifth-Gen Ford Explorer B-Pillar Was Carved Out Over Shoe Clearance Issue: Exclusive

The process of new vehicle development is interesting and oftentimes complicated, one driven by all kinds of factors, stakeholders, and nuances. Many things go into this process, ranging from cost considerations and learnings derived from consumer clinics to features that are oftentimes inspired by the competition, to name just a few. Turns out, one particular feature present in the fifth-generation Ford Explorer was inspired by a Blue Oval employee who famously wore a rather large shoe to cover his equally large feet.

Sources familiar with the matter told Ford Authority a relatively interesting story about then-Ford product chief Derrick Kuzak, who – during a product release review – was unable to get his large shoe to clear the space between the base of the second row rear seat in the fifth-generation Ford Explorer (which was produced between the 2011-2019 model years) and the original B-pillar design. As such, the Explorer team modified the bottom end of the B-pillar, creating roughly an additional inch of clearance, which was apparently all that was needed to fit Kuzak’s larger than average feet. The change in the B-pillar can be seen in the images above and below.

It wasn’t too terribly long after this development – in early 2012 – that Kuzak, who at the time was Ford’s group vice president, Global Product Development, announced that he intended to retire after over 30 years with The Blue Oval. The Michigan native had a profound impact on the automaker and the entire industry over those three decades, helping to redefine Ford and Lincoln vehicles of the era, create the One Ford global product cycle plan, and lead its platform consolidation efforts. Kuzak joined FoMoCo in 1978 as a research engineer and spent time in a variety of leadership positions in both the U.S. and Europe over that time span.

“Derrick’s commitment to product excellence and continuous improvement has allowed Ford to deliver to our customers the industry’s freshest showroom with a complete family of best-in-class products,” said then-CEO Alan Mulally. “At the same time, he prioritized the development of the next generation of talented, experienced product leaders who will continue to deliver for our global customers.”

“It has been an honor to work with so many talented men and women to develop for customers so many meaningful vehicles during the past 33 years,” Kuzak said when he retired from Ford. “The most rewarding accomplishment is to see all of our teams working together around the world to deliver vehicles in each region that are now consistently great to look at, great to sit in and fun to drive – with bold, emotive designs and fuel economy as a reason to buy.”