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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.

An amazing Group B rally car collection heads to auction

Kicking off in 1982, the Group B era spawned some of the most fearsome rally cars of all time. The technologically advanced pioneers of all-wheel drive and turbocharging defined a time when automakers had carte blanche to build machines with unrestricted power, without the burden of homologating a large number of road cars to qualify. The results were sometimes deadly, leading the FIA to ban the class after 1986. Now, a collection of seven Group B monsters is headed across the block in Paris as part of the Artcurial auction, held in partnership with France's famed Retromobile show. The show has been delayed to June, however. There's a 1985 Peugeot 205 Turbo 16, one of 20 Evo II models that helped the company achieve two championships in Group B's short run. This particular example was driven by world champion Timo Salonen at the 1986 Swedish Rally, where it finished seventh due to an oil filter seal failure. Bruno Saby subsequently drove it at the 1986 Tour de Corse and Peugeot entered it at the 1986 Acropolis Rally as well. It's still registered to Peugeot Talbot Sport and represents a French technological achievement, according to Artcurial, comparable to the Concorde or TGV train. Representing Italy are a pair of Lancias in the iconic Martini livery. The Lancia 037 helped Bel Paese clinch its only Group B victory in 1983, after a hard-fought rivalry with Audi. It's one of the few Group B cars that weren't AWD, achieving its success the old-fashioned way, through lightness and superb handling. A second Lancia, a 1986 Delta S4, was the culmination of the Italian firm's later Group B efforts and one of Saby's favorites. While Group B was no more in 1987, the S4 was the predecessor to the Delta Integrale that would dominate WRC from 1987 through 1992. While the collection also includes greats like a Ford RS200, Renault 5 Maxi Turbo, and MG Metro 6R4, the centerpiece is the Audi Quattro Sport S1. The ultimate Group B machine, it introduced all-wheel-drive and turbocharging to the sport. It also employed the wildest use of wings and air dams to generate downforce. Tunable up to 590 horsepower, it could rocket to 60 mph in about three seconds. The car offered for sale came straight from Ingolstadt, a 1988 model built for the Race of Champions of ex-Group B cars. The collection was amassed in the late 80s and early 90s, not long after Group B's dissolution.

EPA says fuel economy test for hybrids is accurate

The EPA says it stands behind its fuel economy test for hybrid vehicles following controversy about the testing process after Ford C-Max Hybrid customers and automotive journalists alike struggled to achieve 47 miles per gallon, the advertised mpg number, Automotive News reports. Ford responded to the issue almost two weeks ago by claiming that a 1970s-era EPA general label rule was responsible for the inaccurate mileage numbers, rerating the C-Max Hybrid's mpg numbers and offering customers rebates. Ford later said it didn't overstate the C-Max Hybrid's fuel economy and that it was surprised by the low numbers.
Ford technically didn't do anything wrong because it was following the general label rule, but agency regulator Christopher Grundler says the automaker was exploiting a loophole when it came up with the hybrid C-Max numbers, and that the testing process remains accurate. The general label rule allows vehicles that use the same engine and transmission and are in the same weight class to share fuel economy numbers, but it doesn't take into account other factors such as aerodynamic efficiency, which affects hybrids more drastically than non-hybrid vehicles. Ford originally used the Fusion Hybrid economy figures for the C-Max Hybrid and claimed the engineers didn't realize that its aerodynamic efficiency would affect fuel economy as much as it did.