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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.

Entertainment Weekly gets a peek into the 'Ford vs. Ferrari' film

The 20th Century Fox film "Ford v Ferrari" is scheduled to open Nov. 15. The movie tells a story enthusiasts can't get tired of, and that Ford has turned into two profitable automotive revivals: the double-cross that led to the no-expense-spared revenge that spawned the Ford GT40 and four successive victories at Le Mans. Entertainment Weekly spoke to the primary actors in the piece and got shots from the set. Matt Damon plays Carroll Shelby, the man Ford recruited to run the GT40 program after the race car performed poorly in its first year of international racing in 1964. Christian Bale plays Ken Miles, an English version of Shelby who could build and drive winning cars. Miles was so good that when racing one of his "Miles Specials," a Cooper-Porsche he improved and drove for California Porsche dealer Johnny von Neumann, he beat the factory Porsches so often that the Stuttgart automaker took Miles' car away. The movie focuses on the first year of the GT40's winning run, in 1966 after the car had become the GT40 MkII. Bale calls the story a "David vs. Goliath vs. Goliath" battle, because Shelby and Miles had to fight Ford as well as Ferrari. "It's these two friends figuring out how do you deal with these a–holes in suits who know nothing about racing," he said. And even though the cars won the fight on track, the two men didn't always win the fights with their paymasters. The three-way finish Ford staged at the end of the race cheated Miles of victory. Miles had been laps ahead of the second-place GT40 driven by Bruce McLaren at the time, but slowed down to let the car catch up. After the three-abreast finish, race organizers said McLaren's car started the race behind Miles, and by finishing with Miles had covered 60 feet more than Miles during the race. They declared McLaren and Chris Amon the winners. The story of how they got to that point — which director James Mangold called "Butch and Sundance in the world of racing" — promises more twists and turns than the Le Mans circuit, and some open flame; video on YouTube shows Damon-as-Shelby being set on fire in one scene. We admit to a bit of concern when Mangold says, "This is much more of a relationship movie and less a historical document." Yet it sounds like he's done his best to get the racing right, so all won't be lost no matter what. Head over to EW to check out the full story and more photos.

Ford offering factory-spec EcoBoost reflashes that don't void warranty*

Buy a supercharger or cold-air kit from Ford Racing and a Performance Calibration handset comes with it to reset the ECU for the upgrade. Now Ford Racing is offering the ProCal handset a la carte for $595, allowing you to reflash the ECU on your EcoBoost-equipped ride to extract more of its inherent capabilities without any additional upgrades. It gives you control of variables such as throttle response, idle speed and turbo wastegate control, among others. As for that warranty asterisk, the press release says enthusiasts can up the power "while maintaining the Ford-backed limited warranty." However Ford Motor Co. and Ford Racing are separate entities, and, best we can tell, when you reflash the ECU, your Ford warranty gets supplanted by the Ford Racing warranty. Say you bought a 2014 Ford, that means your five-year, 60,000-mile warranty becomes Ford Racing's three-year, 36,000-mile warranty, if we're reading the fine print correctly. If you have an older car and have driven more than 36,000 miles, then your warranty options are kaput, at least as far as a Ford in-house option. If have warranty concerns, you might also want to consider having a dealer perform the reflash, or at least ask about it. Once you've got past the small print, what about the numbers? At the moment Ford Racing offers tunes for the 2.0-liter EcoBoost in the Focus ST and the 1.6-liter EcoBoost in the Fiesta ST, and we're told there's a 90-pound-foot boost in torque at the crank after you've pressed the right buttons. Anecdotal evidence from a commenter at Road & Track says he went from 252 horsepower at the flywheel to 254 hp at the wheels, and 272 lb-ft at the flywheel to 354 lb-ft at the wheels, but we can't be sure that his adjustments were within Ford Racing specs. Your mileage, naturally, may vary. What about custom numbers for the 2.3-liter EcoBoost in the 2015 Ford Mustang? They aren't ready yet, but we're told we'll get something by the end of next year. Featured Gallery 2015 Ford Focus ST News Source: Ford, Ford Racing via Car and Driver Aftermarket Ford Technology ecoboost ford focus st ford fiesta st ford racing