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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.

The Stig drives Forza-liveried Ford Focus RS to Gamescom

Auto shows typically present the best opportunities for the public to check out the latest metal the industry has to showcase, but European enthusiasts won't need to wait until Frankfurt or Geneva to see Ford's new performance machinery up close. That's because they'll be able to check out the new Ford GT and Focus RS at the Gamesom expo that opens today in Cologne. But it won't be just any Focus RS, and it won't be driven there by just any old driver. To mark the European debut of Forza Motorsport 6 – whose cover is adorned by the new Ford GT – the Blue Oval automaker has had gamers help design a special livery for the new hot hatch. Wrapped in red, white, and blue with images of the new GT, the unique Focus will be driven by none other than The Stig himself from Top Gear. (Or at least someone in a similar white racing outfit, at any rate.) His Royal Stigness won't have far to go, as Ford's European headquarters are located right there in Cologne (or Koln as the locals call it), less than a half-hour drive down the Rhein river to the Koln Messe where the show will take place. There it'll be showcased alongside the new Ford GT as well, giving gaming fans the chance to check out some very fast Fords up close and personal. Related Video: Aug 4, 2015 | COLOGNE, Germany Ford GT and Gamer-Customised Forza Focus RS to Star During Gamescom; Top Gear's The Stig Helps Unveil One-Off Design - Customised new Focus RS with unique livery designed by players of Forza Motorsport for Xbox unveiled ahead of 2015 Gamescom exhibition in Cologne, Germany - The Stig from BBC's Top Gear drives Forza Focus RS to pre-show event - Visitors to Gamescom – Europe's largest interactive games trade fair – will also see all-new Ford GT supercar on show COLOGNE, Germany, Aug. 4, 2015 – A unique all-new Ford Focus RS featuring an exterior designed by players of Forza Motorsport for Xbox was unveiled today at a special Microsoft event, ahead of the international 2015 Gamescom event in Cologne. The special Forza Focus RS was driven to the event – and accompanied during the evening – by the Stig from BBC's Top Gear, who will feature in the new Forza Motorsport 6 game for the Microsoft Xbox One console. The all-new Focus RS is the third generation of Focus RS cars, following models launched in 2002 and 2009.

Shelby boosts production of 575-hp Raptor on early demand

Shelby American unveiled its all-new Shelby Raptor at the New York Auto Show last month, saying that it would build just 100 examples of its off-road bad boy, a pickup priced at $17,995 over the cost of the donor Ford F-150 SVT Raptor. But the Las Vegas outfit apparently underestimated just how popular the supercharged 575-horsepower 4x4 would actually be.
Strong early demand reportedly has Shelby singing a whole new tune, as the company is now saying it will build upwards of 500 units annually. While the increased production will likely make for at least 400 more happy owners, those who were on the original short list - possibly speculating on future values - might not be grinning as much. Needless to say, the company has assured everyone that each and every one of the modified Raptors will still be listed in the official Shelby registry.
Keep in mind that Ford isn't sitting idle on its trophy-truck-for-the-street, either. The company will reveal its own 2014 F-150 SVT Raptor Special Edition this month.