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How Ford secretly used customers to test its aluminum F-150 [w/video]

Automakers getting clever about disguising development vehicles isn't anything new. Between mules wearing the sheetmetal of other cars and prototypes decked out in as much camouflage as is practical, automakers know how to make it very difficult for the general public to get an exact idea of what kind of vehicle is in development. Ford, though, is rapidly becoming the master.
We knew that the Blue Oval originally tested the durability of the aluminum construction being used for the 2015 F-150 by building an all-aluminum 2014 truck and entering it in the Baja 1000 off-road race. That's no longer a secret. What we didn't know, though, is that the aluminum development dates back to before even that, and that some of the people in question had no idea what it was they were working with.
Ford says this is the first time prototypes have ever been handed over to the public.

IIHS crash tests second F-150 bodystyle

Sometimes, being the king comes with some extra scrutiny. At the urging of Automotive News, the Ford F-150 is the first truck to have multiple cab configurations crash tested by the Insurance Institute for Highway Safety. According to Automotive News, IIHS was preparing to release the crash-test report on the 2015 F-150 after the safety watchdog evaluated the popular, four-door SuperCrew body. However, the agency learned from AN that configuration contained steel bars welded around the front wheels for added protection. Those reinforcements aren't on the other cab variants, and IIHS is now going back to check a SuperCab without the strengthening to check its safety performance, as well. While the added bars might help the SuperCrew score better in the vital but difficult small-overlap front crash test, there's no guarantee that's their sole purpose. As the head of the IIHS crash lab Joe Nolan indicated to Automotive News, if Ford were just trying to beat the system the company could only put the reinforcement on the driver's side where the agency does the small-overlap test. Also, when the National Highway Travel Safety Administration checked the latest F-150, the Feds gave all three cab styles top, five-star overall ratings. Due to the additional testing, IIHS won't have the F-150's scores ready until July, according to Automotive News. Starting next year, the cab variants of other trucks will also starting being crash tested by the agency. Related Video:

Lincoln Continental production likely to shift to Flat Rock

Lincoln production may be returning to Michigan, according to a new report from Automotive News. While the brand's current big sedan, the MKS, is built alongside the Ford Taurus, Ford Explorer, and their Police Interceptor counterparts at the Blue Oval's Chicago, IL factory, the production version of the Continental won't be screwed together in the Windy City. According to AN, "industry sources" claim the Continental will join the Ford Mustang and Ford Fusion – on which the big Lincoln is loosely based – at the company's Flat Rock, MI factory. The move isn't just based on convenience, though. Ford is selling a lot of Explorers, and shifting Lincoln production away from Chicago Assembly frees up production capacity for the popular SUV. "Chicago Assembly Plant is vital to our global manufacturing footprint and will continue to manufacture the Ford Taurus, Ford Explorer and Police Interceptor vehicles even after we phase out production of the MKS in 2016," Ford told Automotive News. "We will continue to match production to demand." Looking at the numbers further backs up the argument against Lincoln production in Chicago. Last year alone, Ford built nearly 285,000 Explorers and over 73,000 Taurus sedans, compared to just 8,300 Lincolns. Finally, as AN tells it, Ford is almost telegraphing the Continental's arrival in Flat Rock. The facility has a four-week shut down scheduled from June 15 through July 13, which is twice as long as the typical summer vacation, while there's another two weeks off slated for September. Related Video: