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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.

Chicago Auto Show: The really big reveals from shows past

The 2024 Chicago Auto Show may seem like a shell of its former self, but it still holds the title of the largest consumer auto show in the United States. It didn't get that reputation simply by being efficiently produced or convenient for locals desperate for something to do in February — it earned it over decades of breaking automotive news and powerhouse reveals, eventually earning an informal designation as America's truck show.  2024 may be a down year for Chicago, but let's not forget all of the great things that have come out of it, historically. Here's a look at some of our staff favorites. Bet you didn't know about a few of these cars that were first revealed in the Windy City.    2008 Dodge Challenger SRT-8  I didn't just pick this one as a former Challenger owner, but instead to illustrate just how many cool Chicago debuts we take for granted. Chrysler often chose its home turf to debut new cars, so the few times its unveilings happened elsewhere tend to stick in our minds. The first Challenger SRT-8 was kind of garbage, if we're being honest. I mean, who buys a race-bred, V8-powered muscle car without a limited-slip differential? But the SRT-8 formula evolved over time into something truly special, and what we saw in Chicago was essentially the early version of the Scat Pack, which was ultimately very successful for Dodge. And who would have thought we'd be here, 15 years later, still talking about that debut? And still loving these big Mopars, flaws and all. — Associate Editor Byron Hurd SHO time in Chicago IÂ’ll always have a certain fondness for the return of the Taurus SHO at the 2009 Chicago Auto Show. Chicago has always leaned truck and van heavy for press reveals, but every now and then, as this list illustrates, something spicy would appear. The return of the SHO as a high-powered successor to the original that ran from 1989-1999 gave enthusiasts hope for FordÂ’s performance business, especially for sedans. With a 3.5-liter EcoBoost V6 packing 365 hp, all-wheel drive and five-spoke wheels, the SHO was a nice upgrade from the lower-rung Taurus models. It was a bit more sedate than the original SHOÂ’s Yamaha-sourced V6 that teamed with a five-speed manual transmission, but still a worthy response to the Chrysler 300, Dodge Charger and later the Chevy SS. The SHO — Super High Output — begat things like the Fusion ST and gave Ford solid four-door performance for the rest of the decade.

Xcar flogs the 2015 Ford Focus ST

There's an inevitable dilemma that practically every auto fan eventually faces, at least other than Jay Leno and Jerry Seinfeld, and that's the tradeoff of performance, practicality and perhaps most importantly, money. Parking the fabled supercar in the garage might be the wish, but for most folks bigger responsibilities – like a family – just don't allow that dream to be a reality. In the view of XCar Films, this intersection of needs and wants is where vehicles like the latest Ford Focus ST provide a fantastic compromise between exciting driving and everyday practicality. Xcar hops into Ford's recently refreshed European hot hatch to illustrate its abilities as both a hauler for the small family on the move and for the driver who just wants to go. The Blue Oval left the powertrain alone for the ST's update, but sharpened the exterior styling, revised the interior and retuned the front suspension and steering. Being realistic, no one is ever going to get behind the wheel of the Focus ST and mistake it for a Porsche, but that's not really the point. Instead, buyers get to put a smile on their face from time to time and still maintain life's other responsibilities. Related Gallery 2015 Ford Focus ST (Euro-spec) View 14 Photos News Source: Xcar Films via YouTubeImage Credit: Related images copyright Ford Ford Hatchback Performance Videos ford focus st xcar xcar films