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Automakers' rush on aluminum may result in shortage

Aluminum is the new buzzword in the automotive industry. The latest Range Rover and Range Rover Sport both take advantage of the lightweight material to shave huge amounts of body fat (only it's called "aluminium" over there). Audi and Jaguar have been using the stuff for years in their A8 and XJ, respectively, and now, aluminum is going mainstream, arriving on the 2015 Ford F-150.
While we're excited to see aluminum make an impact outside the premium market, its widespread adoption apparently won't come without some problems, notably in terms of supply. "There isn't an automotive manufacturer that makes vehicles in North America that we're not talking to," Tom Boney, of Novelis, the largest global supplier of aluminum sheetmetal, told The Detroit News.
According to Boney, Ford's use of aluminum on such a large scale has forced auto manufacturers in "every boardroom" to reconsider their plans following the F-150's unveiling, for one simple reason: there's not exactly enough aluminum to go around, at least in the short term. The auto industry presently only accounts for six percent of the aluminum sheet produced, but as the material is adopted by more and more brands, that figure is expected to swell to 25 percent within the next six years.

NHTSA advances investigation of Ford Crown Victoria headlights

The National Highway Traffic Safety Administration is opening a preliminary evaluation into reports of suddenly failing headlights on 517,945 examples of the 2003-2005 Ford Crown Victoria and Mercury Grand Marquis. The government started looking into this problem in April when the North Carolina Consumers Council filed a defect petition with the agency. Now, the inquiry has moved to the next step. According to NHTSA's documentation (as a PDF), it examined its own database and worked with Ford to come up with a total of 3,609 complaints of the front lighting control module suddenly failing. When this happens, drivers lose the low-beam headlights, but the high-beams can be used by holding the stalk. Sometimes turning the switch off and on fixes the issue. Additionally, there are 15 allegations of crashes, and one reported shoulder injury. NHTSA's preliminary evaluations "evaluate the scope, frequency, and consequence of the alleged defect" and don't necessarily lead to a recall. NHTSA looked into this problem once before in 2008 and 2009 and decided that a recall wasn't necessary. Ford also extended the warranty on the front lighting control module for these vehicles. INVESTIGATION Subject : Loss of headlights Date Investigation Opened: AUG 10, 2015 Date Investigation Closed: Open NHTSA Action Number: PE15028 Component(s): EXTERIOR LIGHTING All Products Associated with this Investigation Vehicle Make Model Model Year(s) FORD CROWN VICTORIA 2003-2005 MERCURY GRAND MARQUIS 2003-2005 Details Manufacturer: Ford Motor Company SUMMARY: After receiving a defect petition (DP15002) concerning the loss of headlights and other exterior lighting in model year (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles, the Office of Defects Investigation (ODI) analyzed Vehicle Owner Questionnaire (VOQ) complaints received from consumers and identified a total of 605 reports (for all submission dates) alleging headlight failure. The complaints indicate failures of both low beam headlights typically while driving, a defect condition that was evaluated under a prior ODI investigation (PE08066). Most consumer VOQs indicate that the headlights failed suddenly and without warning leaving the driver with no forward lighting, however some report the headlights flickered or dimmed prior to turning off. In some cases drivers were able to turn the headlights back on after a period of time while others reported the headlights would not come back on at all.

Focus STs for SEMA include Lotus and Gulf liveries, rally-fied police car

Ford, as we mentioned on Saturday, is pulling out all the stops for November's SEMA show, bringing 57 vehicles to the Las Vegas event. Ford will be staggering the release of its SEMA flotilla, though, so expect to hear a lot about the new additions to the fleet in the weeks to come. We already showed you the Fiesta, Fiesta ST and Mustang models that made up the first batch of SEMA cars. Next up, we have a quartet of modded Focus STs joining Ford's SEMA roster.
Our first Focus ST (pictured above) sports the legendary livery of Gulf Racing. The orange-on-blue scheme, which Ford helped make famous at the 24 Hours of Le Mans, has been updated for 2013, with a more vibrant blue. This ST was built by Universal Technical Institute, while the exterior was done by Neil Tjin of Tjin Edition. Side exhausts, a Vortech supercharger and a Motiv Concepts high-flow cat allow the ST to breathe a bit easier, while Forgestar wheels contrast well with the iconic paint scheme.
Focus ST number two has been done-up by PM Lifestyle and is inspired by "Southern California car culture." Sporting a sleek, pale blue paint job, there's also no shortage of carbon fiber on the car's exterior. The 2.0-liter, turbocharged, four-cylinder engine has been massaged by the likes of Banks Power, COBB Tuning and Ford Racing, while the suspension is wearing a shiny, new set of coilovers and sway bars. The meaty brakes, tucked behind 19-inch, Rotiform wheels, come from Wilwood, while the cabin has been fitted with a pair of Sparco Chrono seats and five-point, Schroth harnesses.