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Ford Gets The Aluminum F-150 Ready For Prime Time

Russell Barnett, a Ford dealer in Tennessee, is ready for aluminum. Ford is using the metal almost exclusively in body of the 2015 version of its best-selling F-150 pickup, which starts arriving at dealerships next month. Barnett is already answering customers' questions about the truck. And he's updated his repair shop not only for the F-150, but in anticipation that other Ford brands such as the Mustang will eventually make the switch from steel. But, just in case, he ordered some extra steel-bodied 2014 pickups. "There will be some people who won't want to change for a while," says Barnett, who says pickups make up around half of the annual sales at his dealership in rural Winchester. Ford is doubling down on aluminum, which is lighter - and more expensive - than steel but just as tough. The new truck is the company's response to customers' requests for a more fuel-efficient and nimbler pickup. Fordhopes the advantages outweigh customer doubts about the durability of aluminum or potential repair costs for the pricier metal. It's a big risk. So far this year, one out of every three vehicles Ford sold in the U.S. was an F-Series pickup. Morgan Stanley estimates F-Series trucks account for 90 percent of Ford's global automotive profit. On Tuesday, it kicked off production of the new truck at its Dearborn Truck Plant, four miles from the company's headquarters. "Yeah, this is a risk, but it's one well worth taking." said Bill Ford, the company's executive chairman, as he stood alongside the assembly line. "For our customer, this is a big, big leap forward." The trucks have been the best-selling vehicles in the U.S. for 32 straight years; last year, Ford sold nearly 100,000 more full-size pickups than General Motors. Aluminum isn't new to the auto industry, but this is the first time it will cover the entire body of such a high-volume vehicle. Ford made 647,697 F-150 pickups at its two U.S. plants last year; that's one every 49 seconds. If Ford's bet pays off, it could pad its lead in the lucrative truck market. More importantly, aluminum "future proofs" the truck - and the company - in an era of rising fuel economy standards, says Karl Brauer, a senior analyst with Kelley Blue Book. Ford will announce the truck's fuel economy figures later this month. That could determine if it steals customers away from the Silverado or Ram. Truck buyers are among the most loyal in the auto market.

Ford UK exec says EVs are a good way to lose a fortune

Stateside, Ford execs are quick to point out the automaker's expansion in the plug-in sector. And despite a minimal presence in the pure EV space, the Blue Oval has been promoting its plug-in vehicles as part of an overall effort to boost fleetwide fuel economy. Too bad the company's UK chief didn't get the memo. There's "no point in us getting behind [EVs] and losing a fortune" - Ford's Mark Ovenden Mark Ovenden, speaking rather frankly at the Geneva Motor Show recently, said he didn't have real high hopes for substantial electric-vehicle adoption and said the company's money was better spent on smaller gas- and diesel-powered engines, the UK's Daily Mail says. Ovenden said of EV development that there was "no point in us getting behind it and losing a fortune," adding that his goal was to have variants of Ford's EcoBoost engine in 40 percent of the company's vehicles. Ford has about a 15-percent market share in the UK. The UK doesn't appear to be as kind to the EV as the US. Nissan last year cut the price of its all-electric Leaf there last year by about $4,000, while the company rolled out a promotion for the Leaf late last year, including allowing Leaf drivers to borrow a gas- or diesel-powered Nissan for free for as long as two weeks a year during the first three years of Leaf ownership. In the US, Ford sold just 229 Ford Focus Electrics during the first two months of the year after moving 1,738 units in 2013.

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.