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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.

Hybrid, electric campers take center stage at Germany's motorhome trade show

Car companies from all over the automotive spectrum will make international headlines next week by presenting hybrid and electric cars at the biennial Frankfurt auto show. Camper van and motorhome manufacturers got a head start on the rest of the industry by presenting their green solutions at the Dusseldorf Caravan Salon. The show confirms electrification is present in the leisure segment, too. German camper experts Dethleffs introduced a plug-in hybrid, pop-top camper based on the full-size Ford Transit van. Called Globevan e.Hybrid, it relies on a 126-horsepower drivetrain built around a turbocharged, 1.0-liter EcoBoost three-cylinder engine. The system can power the camper on electricity alone for up to 31 miles. Adventurers who leave with a full tank and a full charge enjoy 310 miles of driving range, which is an impressive figure for the camper van segment. Charging the battery pack takes 5.5 hours when using a regular household outlet, according to the manufacturer, or three hours when hooking it up to a quick-charging station. Globevan production is tentatively scheduled to begin in 2020, and pricing starts at 75,000 euros, a sum that represents approximately $83,000. EFA-S took electrification a step further. Starting with a Fiat Ducato, a van known as the Ram Promaster in the United States, it yanked out the turbodiesel engine and replaced it with a 140-kilowatt electric motor fed by an 86-kilowatt-hour lithium-ion battery pack. The company pegs the camper's driving range at up to 186 miles, a relatively low figure which hardly reflects how most vacationers use their van. The pack takes four hours to charge, Auto Motor und Sport learned. While sustainable, zero-emissions tourism is difficult to argue against, the Ducato-based camper suffers from two serious setbacks. First, the battery pack makes it so heavy that it can't be driven with a regular license. It's considered a heavy commercial vehicle. Second, its 160,000-euro (about $177,000) price tag makes it twice as expensive as a diesel-burning model, and puts it in the same price range as much bigger, more powerful, and more luxurious models. EFA-S will nonetheless move forward with production in 2020, though it plans to build no more than 30 units. The caravan Salon is not only about hybrids and electric cars, however.

The Stig drives Forza-liveried Ford Focus RS to Gamescom

Auto shows typically present the best opportunities for the public to check out the latest metal the industry has to showcase, but European enthusiasts won't need to wait until Frankfurt or Geneva to see Ford's new performance machinery up close. That's because they'll be able to check out the new Ford GT and Focus RS at the Gamesom expo that opens today in Cologne. But it won't be just any Focus RS, and it won't be driven there by just any old driver. To mark the European debut of Forza Motorsport 6 – whose cover is adorned by the new Ford GT – the Blue Oval automaker has had gamers help design a special livery for the new hot hatch. Wrapped in red, white, and blue with images of the new GT, the unique Focus will be driven by none other than The Stig himself from Top Gear. (Or at least someone in a similar white racing outfit, at any rate.) His Royal Stigness won't have far to go, as Ford's European headquarters are located right there in Cologne (or Koln as the locals call it), less than a half-hour drive down the Rhein river to the Koln Messe where the show will take place. There it'll be showcased alongside the new Ford GT as well, giving gaming fans the chance to check out some very fast Fords up close and personal. Related Video: Aug 4, 2015 | COLOGNE, Germany Ford GT and Gamer-Customised Forza Focus RS to Star During Gamescom; Top Gear's The Stig Helps Unveil One-Off Design - Customised new Focus RS with unique livery designed by players of Forza Motorsport for Xbox unveiled ahead of 2015 Gamescom exhibition in Cologne, Germany - The Stig from BBC's Top Gear drives Forza Focus RS to pre-show event - Visitors to Gamescom – Europe's largest interactive games trade fair – will also see all-new Ford GT supercar on show COLOGNE, Germany, Aug. 4, 2015 – A unique all-new Ford Focus RS featuring an exterior designed by players of Forza Motorsport for Xbox was unveiled today at a special Microsoft event, ahead of the international 2015 Gamescom event in Cologne. The special Forza Focus RS was driven to the event – and accompanied during the evening – by the Stig from BBC's Top Gear, who will feature in the new Forza Motorsport 6 game for the Microsoft Xbox One console. The all-new Focus RS is the third generation of Focus RS cars, following models launched in 2002 and 2009.