Originally posted by Paul the Sunman So why wasn't the cheapest and easiest course of action to update the 60-250 with HD, new SDM, and baffle removed?
Redesigning a lens for FF coverage and changing the focus mechanism = basically a new design.
Having spent many years managing electronics manufacturing operations of various kinds, I daresay that most don't have a clue what redesigning something entails. There are literally hundreds of parts, many of which are molded/tooled, and any such parts that will not work in the new design have to be redesigned, then re-tooled from scratch, which is a long and expensive process.
Added to that would be new focusing mechanisms which have to be fitted mechanically, extensively tested, then sourced and of course programmed to work in the new design.
Lastly, and certainly not least would be the optical design, which is actually probably closer to first in the design timeline. The lens elements and focusing groups dictate the size and position of the glass, which dictates the overall size and then dictates the places that sensors and motors have to go to drive the focus, zoom rings and aperture, and that dictates tooled/molded parts needed to make it all work.
It is far simpler/faster/cheaper to take an existing design and re-tool the mount parts, develop the firmware for the new body protocol and specify what coatings you want. Look at the comparo of both lenses above and you can see how little of the tooled/molded parts had to change: basically none except any associated with the mount. The same is undoubtedly true of the optics, focusing mechanism and aperture control as well.