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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.

Jurassic Park made a big impact on these Jeep drivers

For a certain cohort of young folks, Jurassic Park is a touchstone film from their childhood. Not only did it play into practically every little boy's love of dinosaurs, the movie included some great action scenes and special effects that still hold up today. In its latest video, The Aficionauto takes a look the Jurassic Park Motor Pool, a California car club with over 40 fans who created replica vehicles from the iconic film.
The club is made up of an interesting cross-section of people. Many of them were Jeep Wrangler fans that already loved off-roading and Jurassic Park, and liked the idea of bringing them together. Like any close-knit club, it ends up being about community and people coming together to share their interests. It's quite a heartwarming video. Also, be sure to stay until the end because The Aficionauto teases a future Jurassic Park-themed vehicle. Scroll down to check out the motor pool.

Question of the Day: Most degraded car name?

When Ford came up with a not-so-sporty version of the Pinto and slapped Mustang badges on it in 1974, that was a low point for the Mustang name. When Chrysler applied the venerable Town & Country name on perfectly functional but unglamorous minivans, it saddened many of us. But perhaps the biggest demotion for a once-proud model came when, in 1988, General Motors imported a misery-enhancing Daewoo from Korea and called it the Pontiac LeMans. The original Pontiac LeMans was a great-looking midsize car with fairly advanced (for the time) suspension design and engine options including potent V8s and a screaming overhead-cam straight-six. The Daewoo-based Pontiac LeMans was a cramped, shoddy hooptie that served only to ruin the LeMans name forever, while stealing sales from the Suzuki-based Chevrolet Sprint. Sure, using the once-respected Monterey name on the Mercurized Ford Freestar was bad, but Mercury didn't have long to live at that point. I say the downward spiral of the LeMans name was the most agonizing in automotive history. What do you think? Related Video: This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. Auto News Ford Mercury Pontiac Automotive History Classics questions ford pinto names