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Ford opens the doors on its Swedish rally skunkworks

It's always amazing to see how different kinds of racecars are made. Formula One racers are often constructed in modern architectural marvels that hint at some of the cutting-edge technology going into the racing. Conversely, rallying is all about sliding around on a varied course as fast as possible, but it often leaves a vehicle caked in mud. So it makes some sense Olsbergs MSE, or simply (OMSE) rally car shop in Nynashamn, Sweden, shows technological sophistication in a more down-to-earth setting. It builds Ford Fiesta ST racers for Global Rallycross there, and this new video gives viewers a tour through the work.
Former rally driver Andreas Eriksson runs OMSE. These days instead of racing, he and the company's 46 employees are building Ford racers from scratch. A ton of work goes into constructing each one, and according to Eriksson, it takes 400 hours to complete each body. At times, things are so busy that some of the technicians live in the shop in apartments that are on premises. There's even a restaurant to keep them fed. Sadly the dyno room is empty during this visit, though.
By the time OMSE is done, a rallycross car might resemble a Fiesta ST on the outside, but as you see in the video, it's a completely different beast underneath. Check out the work it takes to build one of them, and scroll down to read more about it in the official release.

Ford GT concept adorns Forza 6 cover

Ford has rolled in to the Detroit Auto Show this week with a staggering array of performance machinery, including the new GT Concept, Mustang GT350R and F-150 Raptor. That's the exciting part. The thing is, that most of us won't have the opportunity to drive any of them, let alone really wring them out on the track. Fortunately, they'll all feature in the upcoming release of Forza 6. Not only that, but the new Ford GT will adorn the box cover as well. Featuring on the cover of the latest installment of what Microsoft (citing Metacritic ratings) says is "the highest-rated racing series of the past decade" would be a coveted place of honor for any automaker. The box art for the original version (at least the one first released in North America) featured a modified Acura NSX, followed by a Nissan 350Z drifter on Forza Motorsport 2, an Audi R8 on Forza 3, Ferrari 458 Italia on Forza 4, an SRT Viper on Forza Horizon, the McLaren P1 on Forza 5 and the Lamborghini Huracan on Forza Horizon 2. This, then, will be the first time a Ford will be the poster child for a new version of the popular game. With carbon-fiber construction, active aero and a twin-turbo EcoBoost V6 pumping out over 600 horsepower, it strikes us as a place well deserved by Dearborn's finest. Microsoft and Ford Unveil Ford GT as the Cover Car for "Forza Motorsport 6" Debuting Exclusively on Xbox One Ford's new line of performance vehicles will star in Microsoft's newest and most advanced racing game DETROIT – Jan. 12, 2015 – Microsoft, Turn 10 Studios and Ford unveiled their new collaboration today at the North American International Auto Show, announcing the all-new Ford GT ultra-high performance supercar as the featured cover car in the next iteration of the acclaimed racing simulation franchise for Xbox, "Forza Motorsport 6," launching exclusively on Xbox One. The GT serves as a technology showcase for Ford with its ultra-efficient EcoBoost engine performance, advanced aerodynamics and lightweight carbon fiber construction. It begins arriving in dealerships in select markets globally late next year. In addition, the companies revealed that Ford's performance vehicle line-up will appear in "Forza Motorsport 6." This includes the GT, Shelby® GT350 Mustang and F-150 Raptor debuted by Ford earlier today at the auto show.

Aluminum lightweighting does, in fact, save fuel

When the best-selling US truck sheds the equivalent weight of three football fullbacks by shifting to aluminum, folks start paying attention. Oak Ridge National Laboratory took a closer look at whether the reduced fuel consumption from a lighter aluminum body makes up for the fact that producing aluminum is far more energy intensive than steel. And the results of the study are pretty encouraging. In a nutshell, the energy needed to produce a vehicle's raw materials accounts for about 10 percent of a typical vehicle's carbon footprint during its total lifecycle, and that number is up from six percent because of advancements in fuel economy (fuel use is down to about 68 percent of total emissions from about 75 percent). Still, even with that higher material-extraction share, the fuel-efficiency gains from aluminum compared to steel will offset the additional vehicle-extraction energy in just 12,000 miles of driving, according to the study. That means that, from an environmental standpoint, aluminum vehicles are playing with the house's money after just one year on the road. Aluminum-sheet construction got topical real quickly earlier this year when Ford said the 2015 F-150 pickup truck would go to a 93-percent aluminum body construction. In addition to aluminum being less corrosive than steel, that change caused the F-150 to shed 700 pounds from its curb weight. And it looks like the Explorer and Expedition SUVs may go on an aluminum diet next. Take a look at SAE International's synopsis of the Oak Ridge Lab's study below. Life Cycle Energy and Environmental Assessment of Aluminum-Intensive Vehicle Design Advanced lightweight materials are increasingly being incorporated into new vehicle designs by automakers to enhance performance and assist in complying with increasing requirements of corporate average fuel economy standards. To assess the primary energy and carbon dioxide equivalent (CO2e) implications of vehicle designs utilizing these materials, this study examines the potential life cycle impacts of two lightweight material alternative vehicle designs, i.e., steel and aluminum of a typical passenger vehicle operated today in North America. LCA for three common alternative lightweight vehicle designs are evaluated: current production ("Baseline"), an advanced high strength steel and aluminum design ("LWSV"), and an aluminum-intensive design (AIV).