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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.

Watch Ken Block play traffic cop in ’Top Gear’ teaser

BBC is teasing a new series of 'Top Gear' starring the rally racer and Hoonigans honcho Ken Block and promising that series 25 is "coming soon." Block plays a police officer (with a Los Angeles Police Department badge, no less) in an off-road 4x4 vehicle in the 30-second clip, jumping off obstacles and tearing through dirt in an industrial area near snow-capped mountains. He gives chase to show hosts Matt LeBlanc, in a yellow Ford Mustang, Rory Reid and Chris Harris, who steers a McLaren 570S. It looks like they're having more fun that the rest of us. LeBlanc has said the next season of episodes will aim to attract a younger, more diverse audience with more comedy. Series 25 is expected to launch in spring, perhaps after the wrap-up of the second season of 'The Grand Tour.'Related Video: Celebrities TV/Movies Ford McLaren Off-Road Vehicles Performance Top Gear Ken Block

8 car technologies designed to keep you safe

Technologies are always advancing forward, especially in your vehicle. As more safety technologies are being introduced into the market, it can be hard to keep track of everything. So here are 8 technologies designed to keep you safe on the road. Want more coverage? Head over to http://bit.ly/2CcOngW Ford Kia Mercedes-Benz Subaru Toyota Volkswagen Volvo Autoblog Minute Videos Original Video FCA automatic emergency braking