When it comes to car shopping, most buyers focus on looks, gas mileage, or price, but few stop to question the metal that fails in high-speed collisions. Behind the sleek design and flashy features, some cars are hiding structural flaws that could be deadly in a crash. Lightweight metals and cost-cutting measures are being blamed for poor performance in crash tests, especially at highway speeds. Safety experts have identified several makes and models that consistently underperform when it counts most. If you drive one of these six vehicles, it may be time to take a closer look at what’s really protecting you.
1. Nissan Versa (Pre-2020 Models)
The Nissan Versa is known as one of the most affordable sedans on the market, but its earlier models came with serious safety trade-offs. According to IIHS crash tests, pre-2020 versions showed excessive cabin intrusion during side and frontal impacts. The subpar steel used in the frame absorbed impact poorly, compromising passenger survival space. This vulnerability becomes especially dangerous in highway-speed collisions where force and energy transfer are extreme. While newer models have improved, older Versas are still widely sold on used car lots.
2. Chevrolet Spark
The Chevrolet Spark’s compact size and budget-friendly price appeal to city drivers, but it has some worrying structural flaws. Its lightweight frame is made with thinner gauge metal, which crumples easily in a high-speed impact. In small overlap frontal crash tests, the cabin integrity was rated poor, raising serious red flags about driver protection. Experts have raised concerns that in collisions over 40 mph, the Spark’s frame can’t adequately deflect or absorb impact forces. For buyers prioritizing crash safety, this is a red flag that can’t be ignored.
3. Mitsubishi Mirage
Another subcompact vehicle on the list, the Mitsubishi Mirage struggles under high-speed crash conditions. Multiple evaluations show poor side-impact protection and a weak B-pillar that can collapse inward. The issue traces back to its lightweight body construction and the use of cheaper metals that deform too easily. In collisions at highway speeds, this weakness translates into a greater risk of serious injury or death. Despite good gas mileage and a low sticker price, the Mirage’s structural failings have drawn criticism from safety watchdogs.
4. Ford Fiesta (2011–2019)
Though popular with younger drivers, the Ford Fiesta’s older models have a serious Achilles’ heel: poor structural performance in high-speed frontal crashes. The National Highway Traffic Safety Administration (NHTSA) noted troubling results in crash tests, especially regarding footwell intrusion and body panel deformation. Part of the blame lies in the use of low-tensile-strength metals in key areas of the frame. When stress loads are high, the metal buckles rather than disperses impact forces. Ford ceased production in 2019, but thousands of these models remain on the road.
5. Kia Rio (2012–2017)
The Kia Rio has made strides in recent years, but its earlier models suffered from underwhelming structural integrity. The vehicle scored poorly in side-impact and small-overlap front crash tests conducted by safety agencies. In particular, the metal that failed in high-speed collisions was found in the side rails and roof supports, which bent too easily under pressure. That failure increases the likelihood of passenger compartment intrusion during a serious wreck. Buyers of used models should verify whether safety updates or reinforcements have been applied.
6. Dodge Caliber
Although discontinued in 2012, the Dodge Caliber is still on the used car market and raises major safety concerns. Built during a time of cost-cutting at Chrysler, the Caliber’s chassis includes low-grade metal that performs poorly under crash pressure. High-speed impact tests revealed critical failure in the A-pillar and firewall areas, putting front passengers at risk. The combination of brittle structural material and outdated crash protection features makes it one of the more dangerous used cars still circulating. Drivers looking for a cheap commuter should look elsewhere.
Your Safety Depends on More Than Airbags and ABS
Many drivers assume that modern cars—especially those with airbags and electronic safety systems—will protect them in a crash. But if the metal that fails in high-speed collisions is part of the frame, even the best technology can’t save you. These six vehicles are reminders that not all safety features are created equal, and what’s underneath the surface matters most. Always check crash test ratings, research known structural flaws, and don’t let a cheap price put your safety at risk. You deserve to drive a car that will protect you when it counts.
Have you experienced or noticed issues with structural safety in one of these vehicles? Share your thoughts or experiences in the comments to help inform other drivers.
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