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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.

Question of the Day: Worst year of the Malaise Era?

The Malaise Era for cars in the United States spanned the 1973 through 1983 model years, and featured such abominations as a Corvette with just 205 horsepower (from the optional engine!) and MGBs with suspensions jacked way up to meet new headlight-height requirements. There were many low points throughout this gloomy period, of course. The horrifyingly low power and fuel-economy numbers for big V8s during the middle years of the Malaise Era make a strong case for 1974 or 1975— the years of Nixon's resignation and the Fall of Saigon, respectively— as the most Malaisey years. But then the GM-pummeling debacles of the Chevy Citation and Cadillac Cimarron could make an early-1980s year the low point. 1979, the year of the ignominious Chrysler bailout? You choose! Related Video:

2015 Ford Mustang earns Five Stars from NHTSA [w/video]

We already know that the latest Ford Mustang is a pretty potent pony car in terms of its performance potential, but according to the government, it's a safe choice too. The National Highway Traffic Safety Administration recently released its New Car Assessment Program crash test results for the 2015 'Stang coupe, and it came away with top five-star overall ratings in every evaluation. The Mustang received a five-star overall score and five stars for its frontal, side and rollover ratings. The only minor ding was a four-star result just for the backseat in a side barrier crash. According to NHTSA, "Although not included in the star rating, the rear passenger's thoracic rib deflection was elevated." You can check out the full NCAP evaluation, here. According to Ford, the latest Mustang has twice as many airbags and crash sensors as the outgoing model. NHTSA also likes that the pony car offers a rearview camera and forward collision warning – two of the technologies that the agency recommends buyers getting for added safety. Watch the car crash in the video below. 2015 MUSTANG EARNS HIGHEST VEHICLE SAFETY RATING FROM NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION National Highway Traffic Safety Administration awards the all-new 2015 Mustang a five-star Overall Vehicle Score in its New Car Assessment Program All-new Mustang has twice as many airbags, twice as many peripheral crash sensors and additional pretensioning safety belt technology compared to the outgoing model The new Mustang is the first car to offer four-, six- and eight-cylinder engines that each produce at least 300 horsepower – a 300-horsepower 3.7-liter V6, a more powerful 435-horsepower 5.0-liter V8, and an all-new 310-horsepower 2.3-liter EcoBoost® engine DEARBORN, Mich., Feb. 11, 2015 – The 2015 Ford Mustang received a top safety rating from the National Highway Traffic Safety Administration (NHTSA). The 2015 Mustang earned a five-star Overall Vehicle Score in NHTSA's New Car Assessment Program (NCAP) testing. The New Car Assessment Program is the National Highway Traffic Safety Administration's evaluation program for new vehicle designs established to test for performance against safety threats. Now on sale at Ford dealers, the all-new 2015 Mustang received five stars in the frontal crash test, five stars in the side crash test and five stars in the rollover crash test. "The new Mustang was built from the ground up," said Carl Widmann, Mustang chief engineer.