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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.

Ken Block hoons his Ford F-150 RaptorTrax on the slopes

Ken Block drives Fords. Hoons the heck out of 'em, actually. Mostly Fiestas, but also the occasional Focus or Mustang. But earlier this year, the Gymkhana guru revealed his baddest Ford yet: an F-150 SVT Raptor on tracks. And true to form, here he is putting it to the test in the latest video from Monster Energy and Hoonigan Racing.
Filmed at Baldface Lodge in Nelson, BC, the video pairs Block up with snowboarders Zak Hale and Ethan Deiss for some deep-powder action. You'll want to watch the video for yourself, but the bottom line is that the RaptorTrax beats the heck out of waiting on line for the ski lift. It's enough to make us start to look forward to winter... almost.

Shelby GT500 and Roush Stage 3 go head to head at the drag strip

The Ford Mustang is a brilliantly affordable source of horsepower, with a base 300-plus-horsepower version available for well under $30,000. Jumping up to about $35,000 will get you a solid 420 horsepower from a high-revving V8, while those with some extra disposable income can get a pair of 600-plus-horsepower monsters. Both the Roush Stage 3 with its Phase 3 package and Ford's factory Shelby GT500 even crest the 650-horsepower mark, with 675 and 662 ponies, respectively.
Naturally, someone needed to find out which of these hi-po Mustangs was the quickest. And while this video is quite obviously a dealership commercial, at least there's some solid drag racing between two of the most powerful performance machines available for under $100,000.
With two NHRA drag racers at the wheel, the Stage 3 and GT500 go head to head for three races. Scroll down below to see the results in the full video.