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How Ford switched gears for the all-new F-150

Editor's Note: This story is authored by Julia Halewicz, a senior editor with AOL's Custom Solutions Group. She holds a Masters in Journalism from NYU and has spent her career as an editor of various newspapers, magazines and digital outlets. Last year on the Friday before Labor Day, the 2014 Ford F-150 pickup truck came off the Dearborn assembly line for the last time. After the last seam was welded, the F-150 that had been so beloved by American consumers would begin the transition from traditional steel manufacturing to an aluminum body, and the second phase of Ford's 2007 blueprint for sustainability would begin. Jobs would be created, and Ford would deliver a stronger product to its consumers. It was a moment Ford would call the biggest in the company's 111-year history. Breaking The Mold For some, the change was almost unfathomable. How could a truck be made with aluminum, and why change what clearly was working very well for the company? "We have a saying at Ford that leaders lead," said Doug Scott, the company's truck group marketing manager. "This was an ideal product to make with aluminum-alloy, because lightweighting made so much sense for a truck, because the extent to which you could take weight out of a truck, you could add more value to the customer in terms of more towing, more payload, more durability, more efficiency – so again all this required us to be out in front further out in front that we normally would be to make sure that we would deliver on all those expectations." Ford began the planning process about five years before the first aluminum F-150 would come to market. The company had a lot of questions. What was customer acceptance of aluminum, could they build the truck, and could the truck be repaired out in the field? Finally, Ford needed to determine if there were enough materials available to support the demand for the F-Series. Aluminum vehicles aren't unusual, but had never been built on the scale of the F-150 – approximately one every minute. Ford created two prototypes to determine if the product would meet and exceed consumer expectations. Any change to the vehicle had to be justified in performance, safety and economy. An aluminum truck needed to be safer, lighter, have increased payload, haul more, and have improved fuel efficiency. After driving the prototypes, Ford knew it was ready to move forward. Once the aluminum truck was ready to build, the next challenge was quickly transforming the plant.

2015 Ford Edge Sport [w/video]

The Edge is easy to overlook, especially in Ford's prolific stable of sport utility vehicles. But thanks to new engines, upscale sheet metal and fresh technologies, the Edge has renewed swagger for 2015. Outfitted in the Sport trim, which included the feisty 315-horsepower EcoBoost V6, a stiffer suspension, and unique fascias, my Edge was loaded, and it was priced accordingly. With options, including all-wheel drive, it cost $46,180, which is pretty lofty for a Ford Edge. But, you get a lot of stuff here – features like leather-accented seats, a lane-departure warning system, and active park assist – that make your life more comfortable and safer. It's been a while since I've driven an Edge. And unless you own one, it's probably been a while since you've even thought about an Edge. Now there's good reason to take another look. Driving Notes I really liked the interior. It was simple, clean, and done up in black. It served as a fitting backdrop for the colorful gauges and the Sync with MyFord Touch infotainment system. The interior designers added silver plastic trim and contrasting white stitching on the center console and door inserts to break up the darkness. Leather was used for the steering wheel wrap, door inserts, and console cover, and it conveyed a premium feel. The leather-trimmed seats with suede inserts were comfortable. They looked elegant and felt pleasing. The heating and cooling features were useful for springtime driving and its varied temperatures. The vista sunroof was spectacular. It let in plenty of sunlight and opened long and wide like a retractable stadium roof. Even closed, it still offered a panoramic view of the sky for my passengers, especially those in the second row. Another note on the interior: I had an excellent driving position and an elevated view of the road. When rain began to fall – which has a way of frazzling motorists – I turned up Cat Stevens and motored along blithely. My second-row passengers were also comfy. One remarked on the ample leg- and headroom, and everyone liked the ambient lighting. The cargo area, which offered 39.2 cubic feet of space behind the second row (7 cubic feet more than the previous version), was more than capable for a weekend grocery run. I'll admit, I'm a Luddite when it comes to infotainment systems, and Sync with MyFord Touch has a mixed reputation. Historically, it's been confusing and hasn't always worked as advertised.

Cosworth double-feature is XCar's a drool-worthy look back

While American fans of Ford performance cars in the '80s and early '90s were loving the 5.0 Mustang, Taurus SHO and, for those who wanted to be a little different, the Merkur XR4Ti, British fans of the Blue Oval were getting their own unique take on speed. The Sierra RS Cosworth (which was similar but not identical to the aforementioned Merkur) and later Escort RS Cosworth were the stuff of dreams with huge wings, hood vents and big power for their time and class. XCar Films aims to find out whether it is little more than nostalgia that makes these classics famous or it really is their legitimate performance. Thanks to its Formula One and racing success, Cosworth was already a well-established performance name in the UK by the time it began selling tuned engines to Ford for the Sierra and Escort. The Sierra RS Cosworth hit the scene in 1986 with a turbocharged, 2.0-liter four-cylinder engine with 204 horsepower and rear-wheel drive. Its huge wing at the back signaled it immediately as something special, and it proved to be a performance powerhouse on and off the track. When it was retired, Ford replaced it with the Escort RS Cosworth that used an upgraded version of the same engine with 217 hp, all-wheel drive and an even bigger rear wing to net yet more racing victories. XCar really gets into the spirit of the time, opening the video with the lo-fi grain of '80s and '90s TV, but to find out whether the Cossies stand up to modern scrutiny, you have to watch the video below. Stay tuned until the end to enjoy them at their best with some vintage motorsports footage. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings.