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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.

Thanks for keeping us on our toes, Detroit Auto Show [w/poll]

Here at Autoblog, we love unexpected debuts at auto shows – and judging by our Detroit Auto Show comments and traffic, you do, too. Surprise reveals have been fewer and farther between in recent years with so many ways for vehicles to be teased or leak out, but this week's show has been a revelation. More to the point, it's been a series of revelations, with automakers from around the globe successfully delivering a brace of concept and production surprises. It's made our jobs a lot more exciting and challenging this week, and even though it's actually more work to react and run-and-gun when the sheet is pulled on a surprise reveal than it is to publish an already-written embargoed story, we've had more fun covering this show for you than any domestic show in memory. We hope you've enjoyed the surprises along with us. To that end, borrowing the words of an unnamed automaker PR flack, we'd like to thank the following automakers for enduring "mountain of antacids" and that "creeping sense of paranoia" necessary to keeping ones' wares totally under wraps until the sheets are pulled off the sheetmetal: Buick Avenir concept Chevrolet Bolt concept Ford GT concept Ford Mustang Shelby GT350R Ford F-150 SVT Raptor Hyundai HCD-15 Santa Cruz concept And while we're at it, we'd like to throw in an shout-out to Detroit's substantially revised and revitalized Cobo Center, and in particular, the redone Michelin media center, which is arguably the single best accommodations for writing show stories that we've encountered on the entire international circuit. Well done, everyone. Thank you, and keep the surprises coming. Auto News Detroit Auto Show Buick Chevrolet Ford Hyundai Volvo 2015 Detroit Auto Show

Ford also working on 200-mile EV to compete with Bolt, Model 3

The Chevrolet Bolt is on a lot of people's radars. You may have even noticed friends and colleagues who harbor very little interest in the automotive world, or anything labeled as "green," who have taken notice of a 200-mile electric vehicle coming out of Detroit. Mass appeal is the idea, after all. You can include Ford in the list of interested parties, in this case with the intention of taking direct aim at the Bolt – and, by proxy, the Tesla Model 3 – with an affordable, long-range EV of its own. Ford will unveil its own long-range EV, positioned to compete with Chevrolet, later this year, according to Automobile. Details are very scarce about Ford's plans, but we do know that the Bolt (or whatever the Chevy all-electric hatchback will end up being called) is expected to offer over 200 miles of driving between charges, with a sticker price around $30,000. The other major player, of course, is Tesla's smaller, more affordable sibling to the Model S. The Model 3, also slated to go on sale in 2017, should cost less than $40,000. While Tesla has established itself in the EV world, another long-range EV out of Detroit would win some customers from the California-based startup. For now, though, we'll just have to wait, as Ford remains tight-lipped about its plans for the car. Automobile predicts a possible unveiling at the Los Angeles Auto Show in November, what with California's EV mandate being a driver of strategy for various automakers. Most can agree, though, that a larger field of options – while not ideal for backers of the Bolt or Model 3 – will only benefit the car-buying public. Related Video: Featured Gallery Chevrolet Bolt EV Concept: Detroit 2015 Related Gallery Chevrolet Bolt EV Concept News Source: AutomobileImage Credit: Copyright 2015 Sebastian Blanco / AOL Green Rumormill Chevrolet Ford Tesla Electric Future Vehicles Chevy Bolt ford ev