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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.

Man has surgery to remove T-Bird turn signal that's been in his arm for 51 years

In 1963, real estate agent Arthur Lampitt was driving a new Ford Thunderbird near East Peoria, Illinois on his way to an appointment when he collided head-on with a truck. A massive accident that was so bad that it was originally reported as a fatal crash, Lampitt suffered a broken hip and that became the focus of doctors' efforts. In fact, no one noticed the fact that the turn-signal stalk had been broken off the steering column and had lodged itself in Lampitt's arm. Fast-forward to around ten years ago, when Lampitt set off a courthouse metal detector because of a "slender object, about the size of a pencil" in his arm. Despite that unnerving discovery, the doctor who examined Lampitt said that since it didn't hurt, he needn't worry about it. This year, however, it did start hurting and the affected arm started to bulge. Lampitt decided to have the issue seen to, and suspected it might have something to do with his 1963 accident. When he looked through photos of the wreck taken by a friend, he noticed the turn-signal stalk of the Thunderbird missing and figured that was the culprit. After a 45-minute outpatient surgery, the surgeon verified it: a slim, slightly bent and corroded, seven-inch metal cylinder with a trumpeted end. The surgeon said a protective pocket had formed around it, which is why it could remain in Lampitt's arm so long, but it was still unusual - "We see all kinds of foreign objects like nails or pellets, but usually not this large." Lampitt, who is expected to make a full recovery, says he might make a keychain out of it, once he's done just holding it. News Source: St. Louis Post-DispatchImage Credit: Jesse Bogan, St. Louis Post-DispatchTip: Jon Auto News Ford Coupe accident wreck ford thunderbird turn signal

SEMA crowns Mustang, FR-S as this year's hottest cars in the building

After wrapping up the first day of the 2012 SEMA Show, organizers handed out awards for some of the trendiest vehicles on display. Since the whole point of SEMA is to show off new products available in the aftermarket world for use in cars, trucks and SUVs, each year, the show distinguishes the most popular vehicle in various segments. Not surprisingly, this year's Hottest Car and Hottest Sport Compact are the Ford Mustang and Scion FR-S, respectively, while the Ford F-Series brought home the Hottest Truck and the Jeep Wrangler was named the Hottest 4x4-SUV.
More than 2,000 companies are at this year's show, and the display booths represents a "vote" for each car to determing the trendiest vehicles in each of the four categories. It isn't clear if these awards also take cars brought by OEMs into account, but the Mustang and FR-S were definitely well represented by both OEM and aftermarket show versions.
As usual, the OEMs showed up in force at the this year's SEMA Show exhibiting a variety of cars ranging from production-intent cars like the beastly Ford Mustang Cobra Jet to much flashier rides like Scion's Carbon Stealth FR-S.