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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.

FBI investigating recently fired Ford engineer for espionage

Agents of the FBI are investigating a potential case of industrial espionage involving a recently fired Ford employee. The Dearborn, MI-based manufacturer had its world headquarters searched by FBI agents on July 11, and according to The Detroit News, had warrants to seize recording devices handed over to Ford by Sharon Leach, a now-former Ford engineer.
Leach, who had spent 17 years with the Blue Oval, was fired last month, after Ford Security relieved her of eight Sansa listening devices. The FBI got involved shortly after her dismissal, searching her home on June 20 and seizing some two dozen items, including computers, jump drives and financial records, according to warrants obtained by The News.
Ford has remained quiet on the matter, with spokeswoman Susan Krusel confirming that the automaker was working with the FBI as part of a "joint investigation," while declining to provide any additional details.

Ken Block's 1965 Ford Mustang Hoonicorn RTR and CR Supercars Villain are retro done right

Gymkhana king Ken Block has had a pretty simple car history in his trademark videos, starting out with Subaru Impreza rally cars before moving into Ford Focus racers for the past four installments. His next video, though, Gymkhana Seven, kind of goes back in time.
Rather than the cutting-edge rally racers of past videos, Block will pilot a heavily modified 1965 Ford Mustang, called the Hoonicorn. How heavily modified is it? Well, Block's Hooligan Racing Division, ASD Motorsports and Vaughn Gittin Jr.'s RTR, spent two years working on it, ditching the standard engine and rear-wheel-drive layout and replacing it with a 410-cubic-inch Roush Yates V8. Yes, that's a NASCAR engine, and it produces 845 horsepower.
A NASCAR-powered Mustang would be news in itself, but it's the other powertrain changes made by Block and Co. that really makes headlines. Power is channeled through a one-off Sadev transmission and all-wheel-drive system, meaning that Block has basically married a NASCAR stock car with a WRC racer. ASD also developed the customized suspension, tubular chassis and roll cage. The wide Mustang body is the work of RTR and Block's own Hoonigan Racing Division, while the 18-inch fifteen52 wheels are shod in Pirelli Trofeo R tires that use a specialized compound exclusive to Block.