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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.

Weekly Recap: Ford GT inspires guitar, foosball table, sailboat

Ford design vice president Moray Callum had just wrapped up a briefing on the interior of the Ford GT last month, but something seemed out of place. He grinned and pointed behind him, "You might be wondering why I have a boat behind me," he said mischievously. It was there because Ford set its designers on a mission to stretch and showcase their talents: design non-automotive objects inspired by the interior of the GT supercar. Callum received quite a response, too. His team produced a guitar, a foosball table (yeah bro!), a racing sailboat, a Wi-Fi speaker and some furniture. As the veteran design chief explained, "It's a really great exercise both to highlight our designers' talents, but also to really see how our design philosophy can work and how you can use it and get a common response back from a worldwide design team." Guitar View 25 Photos The objects have been on display this week at the Salone del Mobile furniture and fashion design fair in Milan, Italy, where Ford has had a presence for three years. There's also a light exhibition that apparently was inspired by the GT, as well. While this might seem a little far-fetched for the automaker, Ford said exhibitions like the Salone del Mobile give its designers another way to be creative and ultimately produce striking interior style. Ford wants this to be a differentiator, as research shows consumers are placing emphasis on the layout and features inside when they're making a decision about buying a new car. It's a little light hearted – but it's also potentially big business. Other News & Notes Cadillac CT6 platform could be used for Buick General Motors product chief Mark Reuss said the Cadillac CT6 platform could be used for a large Buick, though "not yet," Automotive News reported. The underpinnings can accommodate rear-wheel or all-wheel drive and would give Buick the large flagship it lacks. The report jibes with comments Reuss made at a roundtable with Autoblog and other reporters at the New York Auto Show. When asked if Buick had space for a large car on the CT6 chassis, he replied, "Yeah, I think it does. Yeah, I think we do." Buick has revamped its lineup in recent years with attractive crossovers and small and midsize sedans, but hasn't added the proverbial flagship that's yearned for by enthusiasts. Buick surprised industry observers with the stylish Avenir concept at the Detroit Auto Show earlier this year that raised the possibility of a halo sedan.

Jaguar design boss admits X-Type was a mistake

History has a way of repeating itself, especially in the auto industry. When Jaguar was owned by Ford, the British brand attempted to field a competitor for the BMW 3 Series, called the X-Type. Based on the bones of a Ford Mondeo, it aped the styling of Jaguar's flagship model, the XJ, while borrowing liberally from the Ford parts bin. That was 2001.
Now, in 2013, Jaguar is planning a new 3 Series challenger based on the platform previewed by the C-X17 Concept, while Ford is attempting to take the latest Mondeo upmarket. The moves have both brands recognizing where, why, and how the X-Type failed. "It didn't look mature or powerful or anything. It was just a car," Jaguar's current head of advanced design, Julian Thomson, told PistonHeads. Basing the X-Type on a front-drive car while giving it styling that was meant for a rear-driver lead to proportions that "were plainly wrong," Thomson told PH. Ford's European head of quality, Gunnar Herrmann, added that the X-Type was "a fake Jaguar, because every piece I touch is Ford."
For what it's worth, the X-Type's successor in the segment will sport rear-drive, with plenty of input from Ian Callum. Thomson described the new model, which would challenge the 3 Series as having, "Big wheels right to the ends of the car, low bonnet, short overhangs, very low cabins." Sounds good to us.