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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.

2016: The year of the autonomous-car promise

About half of the news we covered this year related in some way to The Great Autonomous Future, or at least it seemed that way. If you listen to automakers, by 2020 everyone will be driving (riding?) around in self-driving cars. But what will they look like, how will we make the transition from driven to driverless, and how will laws and infrastructure adapt? We got very few answers to those questions, and instead were handed big promises, vague timelines, and a dose of misdirection by automakers. There has been a lot of talk, but we still don't know that much about these proposed vehicles, which are at least three years off. That's half a development cycle in this industry. We generally only start to get an idea of what a company will build about two years before it goes on sale. So instead of concrete information about autonomous cars, 2016 has brought us a lot of promises, many in the form of concept cars. They have popped up from just about every automaker accompanied by the CEO's pledge to deliver a Level 4 autonomous, all-electric model (usually a crossover) in a few years. It's very easy to say that a static design study sitting on a stage will be able to drive itself while projecting a movie on the windshield, but it's another thing entirely to make good on that promise. With a few exceptions, 2016 has been stuck in the promising stage. It's a strange thing, really; automakers are famous for responding with "we don't discuss future product" whenever we ask about models or variants known to be in the pipeline, yet when it comes to self-driving electric wondermobiles, companies have been falling all over themselves to let us know that theirs is coming soon, it'll be oh so great, and, hey, that makes them a mobility company now, not just an automaker. A lot of this is posturing and marketing, showing the public, shareholders, and the rest of the industry that "we're making one, too, we swear!" It has set off a domino effect – once a few companies make the guarantee, the rest feel forced to throw out a grandiose yet vague plan for an unknown future. And indeed there are usually scant details to go along with such announcements – an imprecise mileage estimate here, or a far-off, percentage-based goal there. Instead of useful discussion of future product, we get demonstrations of test mules, announcements of big R&D budgets and new test centers they'll fund, those futuristic concept cars, and, yeah, more promises.

Time to catch up with Jay Leno's Garage, including his Lamborghini Espada restoration

If you're already jealous of the time, effort and money that Jay Leno can devote to his massive car collection, prepare to get a little greener with envy with this latest video from Jay Leno's Garage. Instead of the usual format of discussing a model for about ten minutes and then taking it out for a test drive, this week Leno gives viewers on a tour of over a dozen projects concurrently happening in his stable. The breadth of the vehicles shown and the things being done to them run the entire span of the automotive hobby. At the same time, Jay's shop is working on just a simple restoration of his 1969 Lamborghini Espada (pictured), and at the other side of the building, the team is rebuilding a wood-bodied 1914 Detroit Electric from scratch. He eventually plans to slot a more modern electric drivetrain into it. If bikes are more your interest, there's a freshly completed Brough Superior just waiting for a ride, and if American models are your thing, a Ford Bronco is getting a Coyote V8 installed into it. You have some very specific tastes if you can't watch this clip and start wishing at least one of these vehicles could be in your own garage. Other than the personal projects his mechanics are working on in the shop, Jay gets to have them all, plus plenty more.