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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.

Ford To Unveil Solar Hybrid Concept Car At CES

Ford plans to unveil at this month's International CES gadget show a solar-powered concept car that offers the same performance as a plug-in hybrid but without the need for a plug. The C-Max Solar Energi Concept car uses a gasoline engine combined with a gizmo that acts like a magnifying glass to concentrate the sun's rays on the vehicle's roof-mounted solar panels. The automaker says the vehicle's estimated combined city-highway mileage is 100 miles (160 kilometers) per gallon. The U.S. auto maker says that by using solar power instead of an electric plug, a typical owner will reduce their annual greenhouse gas emissions by four metric tons. The company says it sold about 85,000 hybrid or electric vehicles in 2013, including 6,300 units of its C-Max Energi plug-in hybrid. The sun-ray concentrator was developed by researchers at the Georgia Institute of Technology and uses what is known as a Fresnel lens, which concentrates light but can be made thinner than a conventional lens. A full day of sunshine is equivalent to a four-hour battery charge, or 8 kilowatts, Ford says. On a full charge, it should have a range of 620 miles (997 kilometers), the same as the C-Max Energi. The concept car also comes with a plug-in port for standard electric charging. Ford says that 75 percent of all trips made by an average driver could be powered by the sun. After showing off the concept car at the convention in Las Vegas Jan. 7-10, Ford Motor Co. says that it will test the vehicle with institute researchers to determine if it's feasible for mass production. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. Related Gallery 2013 Ford C-Max Energi Test Drive View 9 Photos Green CES Ford Alternative Fuels Fuel Efficiency Solar Cars solar car

Ford overlooks the Big Apple in the 2015 Mustang Convertible [w/video]

Ford has done it again. Like in April of 1964, there is once again an all-new Mustang Convertible sitting on the observation deck of New York City's Empire State Building. This has been in the making for a little while, with the first report that Ford would recreate the sky-high publicity stunt coming out a few weeks back.
The process of getting the Mustang up there wasn't exactly easy. A Troy, MI-based company chopped up the new droptop, a necessary evil to get the Mustang on the Empire State Building's only freight elevator that runs to the 86th floor observation deck. But it was slightly more involved than just taking the car apart. The company, DST, built a mockup of the ESB's freight elevators, and then practiced its cuts on a second pre-production Mustang Convertible (measure twice, cut once).
The result of all this work are the images you see above. Yes, sitting in the crisp, morning air of midtown Manhattan, over 1,000 feet up, is this brilliant, Triple Yellow Mustang. Take a look up top for our gallery of images from today's event. You can also scroll down for videos and images of the process leading up to the ESB debut.