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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.

Recharge Wrap-up: Ford 1.0L EcoBoost a hit in Europe; Build a tiny inverter, win $1 million

In Europe, Ford's 1.0-liter EcoBoost engine is the best-selling turbocharged gasoline engine. The three-cylinder motor powers 20 percent of new Fords sold in Europe. Earlier this year, it won its third International Engine of the Year award, and between January and June, it was sold in about 120,000 cars. So far this year, 38 percent of Fords sold in the Netherlands, 35 percent in Denmark and 32 percent in Switzerland have been powered by the 1.0-liter EcoBoost. The engine's turbocharger spins at 248,000 rpm, and provides 24 psi of pressure. The engine produces up to 138 horsepower, depending on the version. Read more in the press release below. When lithium-ion battery packs are retired from the road, remanufacturing, repurposing, and recycling are worthwhile options, according to a study by Mineta Transportation Institute. The study included a cost-benefit analysis of those three options, and found remanufacturing to be the best route. To get the most out of them, batteries should be tested and have their damaged cells replaced then put back to use. Repurposing is the second best option, using the remaining available charge for something besides cars. Recycling on its own isn't profitable, but it could make economic sense with "increased technological breakthroughs." Learn more at Recycling International or download the report here. A smaller inverter for EVs can win you $1 million. The Little Box Challenge is an open competition to build a power inverter with a density of at least 50 watts per cubic inch. Google and the Institute of Electrical and Electronics Engineers (IEEE) are offering the hefty prize to the team that builds the inverter with the highest power density within an enclosed volume of 40 cubic inches. Teams must register by September 30. Read more at Green Car Congress or learn more at the Little Box Challenge website.

NHTSA investigating 500k Ford and Mercury cars for lighting failures

The Ford Crown Victoria and Mercury Grand Marquis might be long gone as new models in showrooms, but the National Highway Traffic Safety Administration might check them out yet again for a potential problem. At the urging of North Carolina Consumers Council, the agency may open another investigation into the front lighting control module on vehicles from the 2003-2005 model years, and NHTSA estimates the issue could affect 517,945 vehicles. If the module stops working, it can cause a complete failure of all forward lighting, including the headlights. NHTSA previously investigated the issue in 2008 and 2009 but found no need for a recall, according to Bloomberg. Ford also extended the warranty on the part to 15 years or 250,000 miles. To prompt this new request, the North Carolina Consumers Council received a letter from a woman experiencing the module's failure. Upon further investigation, the council found 604 complaints of this problem on NHTSA's website, including seven crashes. Furthermore, the group has alleged that dealers told customers that the parts to perform the replacement weren't available, despite the extended warranty. According to the government agency, "A defect petition has been opened to evaluate the issue and make a grant or deny decision." Ford spokesperson Kelli Felker tells Autoblog via email, "We will cooperate with NHTSA, as we always do." You can read the council's complete letter to the Feds in PDF format, here. INVESTIGATION Subject : Loss of headlamp/exterior lighting Date Investigation Opened: APR 01, 2015 Date Investigation Closed: Open NHTSA Action Number: DP15002 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: The Office of Defects Investigation (ODI) has received a petition from the North Carolina Consumers Council, Inc. requesting a defect investigation of an alleged defect condition resulting in headlight and/or exterior lighting failure on 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles. The petition letter is attached for review. The petitioner alleges a defect in the lighting control module that powers the headlights which can result in the loss of vehicle headlights and/or all exterior lighting while driving. ODI has previously investigated this issue under PE08-066 which was closed without a defect finding.