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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.

Hybrid, electric campers take center stage at Germany's motorhome trade show

Car companies from all over the automotive spectrum will make international headlines next week by presenting hybrid and electric cars at the biennial Frankfurt auto show. Camper van and motorhome manufacturers got a head start on the rest of the industry by presenting their green solutions at the Dusseldorf Caravan Salon. The show confirms electrification is present in the leisure segment, too. German camper experts Dethleffs introduced a plug-in hybrid, pop-top camper based on the full-size Ford Transit van. Called Globevan e.Hybrid, it relies on a 126-horsepower drivetrain built around a turbocharged, 1.0-liter EcoBoost three-cylinder engine. The system can power the camper on electricity alone for up to 31 miles. Adventurers who leave with a full tank and a full charge enjoy 310 miles of driving range, which is an impressive figure for the camper van segment. Charging the battery pack takes 5.5 hours when using a regular household outlet, according to the manufacturer, or three hours when hooking it up to a quick-charging station. Globevan production is tentatively scheduled to begin in 2020, and pricing starts at 75,000 euros, a sum that represents approximately $83,000. EFA-S took electrification a step further. Starting with a Fiat Ducato, a van known as the Ram Promaster in the United States, it yanked out the turbodiesel engine and replaced it with a 140-kilowatt electric motor fed by an 86-kilowatt-hour lithium-ion battery pack. The company pegs the camper's driving range at up to 186 miles, a relatively low figure which hardly reflects how most vacationers use their van. The pack takes four hours to charge, Auto Motor und Sport learned. While sustainable, zero-emissions tourism is difficult to argue against, the Ducato-based camper suffers from two serious setbacks. First, the battery pack makes it so heavy that it can't be driven with a regular license. It's considered a heavy commercial vehicle. Second, its 160,000-euro (about $177,000) price tag makes it twice as expensive as a diesel-burning model, and puts it in the same price range as much bigger, more powerful, and more luxurious models. EFA-S will nonetheless move forward with production in 2020, though it plans to build no more than 30 units. The caravan Salon is not only about hybrids and electric cars, however.

Enterprise customer billed $47k for Mustang stolen from rental lot

A weekend rental of a Ford Mustang GT Convertible sounds like a nice, relaxing way to burn some gas, but one Nova Scotia woman's two-day rental is turning into a months-long headache. In early October, Kristen Cockerill picked up the Mustang from Enterprise Rent-A-Car, and she returned it the following day as stipulated by the rental contract. Unfortunately, she dropped the car off on a Sunday - a day on which the particular Enterprise office is closed - and the car ended up being stolen overnight.
Now, two months later, CBC reports that Cockerill received a bill from Enterprise for the full replacement of the car totaling $47,271 (a base 2014 Mustang GT Convertible currently costs $40,349 in Canada). As it turns out, the fine print in the contract says that the renter is responsible for cars dropped off after hours until it can be inspected the next business day - this is also reflected on the key drop seen in the news report video, which states "vehicles returned after hours are the responsibility of the renter until inspected on the next business day."
It's not clear how much, if any, of that amount Cockerhill will be responsible for once her insurance company gets involved, but if the insurance company refuses to pay, Enterprise will bill the amount to the credit card she provided during her rental. While this ordeal is far over for Cockerhill, it's a good reminder for the rest of us to always read the fine print.