1962 Ford F100 Custom Cab on 2040-cars

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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.

Junkyard Gem: 1991 Mercury Grand Marquis LS

Ford's now-defunct Mercury Division first began using the Marquis name in 1967, on a sporty full-size hardtop based on the Ford LTD, then began offering the Grand Marquis beginning in the 1979 model year. These big, boxy luxury sedans were replaced by big, curvy luxury sedans (on the same platform) starting with the 1992 model year, so today's Junkyard Gem is one of the very last squared-off Grand Marquises ever built. The 1991 Grand Marquis (or "Grandma Keith," as many refer to it today) looks nearly identical to its 1979 predecessor at a glance, just as the 2011 model doesn't differ much from the 1992 model. Ford saw no reason to follow short-lived fashion trends with its simple, sturdy rear-wheel-drive sedan. Only two Grand Marquis trim levels were available for 1991: the base GS and the (somewhat) upscale LS. The former listed at $18,741 and the latter at $19,241, which comes to about $41,494 and $42,601, respectively, in inflated 2022 dollars). This interior would have seemed comfortingly familiar to a 1968 (or even 1958) Mercury owner time-traveling to 1991.  This is the optional "full grain leather seating surface," which cost an extra $489 (about $1,083 today). Dig those opera lights! Air conditioning was standard equipment in the 1991 Grand Marquis and its wagon counterpart, the Colony Park. The engine is the good old pushrod 5.0-liter Windsor V8, which would be replaced by a far more modern 4.6-liter SOHC mill in the '92 Grand Marquis. This engine was rated at 180 horsepower. A four-speed automatic was the only transmission available. The early 1990s ended up being the last gasp for padded vinyl roofs being considered mainstream equipment on new Detroit cars; this one was called the "Formal Coach" roof and cost an additional 725 bucks ($1,605 now). Such roofs were still available on a few cars later in the decade, but their time had passed. Why would such a clean Grandma Keith end up in a place like this? That's easy: it got T-boned directly into the right front wheel, mangling the body and bending up the suspension. This damage might have been worth fixing when the car was five years old, but it's a write-off when it happens to a 31-year-old Ford Panther. 1991 Mercury Grand Marquis Commercial - Savings Ad The granddaddy of them all, and on sale in South Texas! Related video: 2008 Mercury Mariner Hybrid test drive Autoblog

How Chevy Silverado, GMC Sierra will take on the Ford F-150 profit machine

FORT WAYNE, Ind. — When General Motors engineers were developing the 2019 Chevrolet Silverado and GMC Sierra pickup trucks, some of them joined public tours of Ford's Dearborn, Mich., factory to watch aluminum-bodied F-Series trucks go down the assembly line. The redesign of the Ford F-Series trucks, launched in 2014, set a new standard for fuel economy and lightweight vehicle construction. But armed with stopwatches and trained eyes, the GM engineers believed they saw problems. "They had a real hard time getting those doors to fit," Tim Herrick, the executive chief engineer for GM truck programs, told Reuters. His team did more intelligence gathering. They bought and tore apart Ford F-Series doors sold as repair parts. Their conclusion: GM could cut weight in its trucks for a lower cost using doors made of a combination of aluminum and high-strength steel that could be thinner than standard steel, shaving off kilograms in the process. These pounds-and-pennies decisions will have major implications in the highest-stakes game going in Detroit: dominance in the world's most profitable vehicle market, the gasoline-fueled large pickup segment. What's more, GM is banking on strong sales of overhauled 2019 Silverados and GMC Sierras to fund its push into automated and electric vehicles — a business many investors see as the auto industry's long-term future. The risks are high given the hits automakers have taken from U.S. President Donald Trump's trade policies. Rising aluminum prices spurred by Trump's tariffs are driving up costs on the Ford's F-Series, while rising steel and aluminum prices likewise drag on GM results. GM also has a significant risk should the United States, Mexico and Canada fail to agree on a new NAFTA trade deal, given GM trucks built at its Silao, Mexico, factory could face a 25 percent tariff if NAFTA collapses. Major profit per truck Interviews with GM executives and a tour at its factory here in northwest Indiana provide a detailed look inside GM's plan for the most important vehicles in its global lineup. These big pickups are everything Tesla's Model 3 or Chevy's Bolt electric car is not. The mostly steel body is bolted to the truck's steel frame, rather than the one-piece body and frame electric vehicles. The majority of trucks will have a V-8 gasoline engine powering the rear wheels — like the classic GM cars of the 1950s. Some Silverados will have new four-cylinder engines, but there is no electric or hybrid offering as of now.