2014 Ford F150 Fx4 on 2040-cars

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2015 Ford F-150 enters production

Ford has given the F-150 a dramatic makeover for 2015, switching to an aluminum body that helps reduce weight by about 700 pounds. Because the truck is dramatically different, Ford also had to change the way it makes the F-150, so we went inside its sprawling factory in Dearborn, MI, this week to see the Blue Oval's new manufacturing techniques in action.
The company has added 850 jobs at the site and upgraded its stamping and tool and die facilities. The body shop is also modernized, and it has been fitted with 500 new robots that join the structures together. The first 2015 F-150 rolled off the line on Tuesday, and the trucks will begin arriving in dealerships in December. Get a closer look at the F-150's unique assembly process in our video.

How Ford's light lab keeps the sun shining on the new Mustang just right [w/video]

Anyone who's bought one of those old school metal shift knobs knows they're really cool until they sit in a parking lot in the sun for a few hours. Then they're not cool at all. Likewise, features such as the aluminum dash on the 2015 Ford Mustang can be all kinds of neat right up until the sun hits it just the right way and sends shards of blinding light through the cabin. The Ford Visual Performance and Evaluation Lab is where engineers figure out how to make sure that doesn't happen.
Cars like said Mustang are parked inside the 30-foot reflecting dome under 6,000 watts of lights that can mimic the sun at any time of day and in any weather condition. Engineers can then spend cold, overcast days inside, testing for interior legibility, glare and reflections on every interior and exterior surface as if it were bright and sunny. They can also learn how a car's sheetmetal and colors will look out of doors, all year round.
Ford showed off the lighting lab without the music and interviews three years ago when the Explorer was being prepared. You can watch it at work again in the video below, and read about it in the press release below that.

Roush getting back into sport compact business with Focus ST mods [w/video]

Roush Performance offers a whole raft of parts for folks looking to tune their Ford Mustang and F-150 models, and now Focus owners can start getting in on the hotted-up action, too. Owners of the 2012-13 Focus and 2013 Focus ST can now get a Roush cold-air intake system, and ST owners can also opt for a high-performance cat-back exhaust.
Although all of these components are now available for order, the parts will ship sometime in July; no word yet on pricing. Down the road, Roush will also offer styling upgrades for the Focus as well as performance tuning upgrades such as engine controller, suspension, wheels and tires. Scroll down for a quick video of what the Focus ST exhaust sounds like, as well as a Roush press release.