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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).

Chris Harris checks out Ken Block's Hoonicorn '65 Mustang

Ken Block's Hoonicorn, which stars in Gymkhana Seven, might still bear a passing resemblance to a vintage 1965 Ford Mustang, but underneath the skin, the car is one of the baddest custom machines to ever do a smoky burnout on the road. The ever enthusiastic British auto journalist Chris Harris is now showing what really makes Block's new ride tick on video, and Harris even gets to go for quite a ride. The only Mustang components really left on the Hoonicorn are the A-pillar, B-pillar and roof, according to Harris. Everything else is ditched to create Block's ultimate Gymkhana tool. The 845-horsepower, 6.7-liter Rousch Yates V8 sits behind the front axle, and the grunt is routed to all four wheels through a Sadev gearbox usually found on Dakar Rally vehicles. The whole drivetrain is packed with cool little touches; like that giant handbrake that also disconnects power from the front wheels when in use. The superlatives about the Hoonicorn could go on forever, but settle in and let a very excited Harris tell you about just some of them. He's like a kid in a candy store here, and the look that combines surprise, fear and joy during his ride with Block is the kind that lacks a suitable word in the English language.

Ken Block's 1965 Ford Mustang Hoonicorn RTR and CR Supercars Villain are retro done right

Gymkhana king Ken Block has had a pretty simple car history in his trademark videos, starting out with Subaru Impreza rally cars before moving into Ford Focus racers for the past four installments. His next video, though, Gymkhana Seven, kind of goes back in time.
Rather than the cutting-edge rally racers of past videos, Block will pilot a heavily modified 1965 Ford Mustang, called the Hoonicorn. How heavily modified is it? Well, Block's Hooligan Racing Division, ASD Motorsports and Vaughn Gittin Jr.'s RTR, spent two years working on it, ditching the standard engine and rear-wheel-drive layout and replacing it with a 410-cubic-inch Roush Yates V8. Yes, that's a NASCAR engine, and it produces 845 horsepower.
A NASCAR-powered Mustang would be news in itself, but it's the other powertrain changes made by Block and Co. that really makes headlines. Power is channeled through a one-off Sadev transmission and all-wheel-drive system, meaning that Block has basically married a NASCAR stock car with a WRC racer. ASD also developed the customized suspension, tubular chassis and roll cage. The wide Mustang body is the work of RTR and Block's own Hoonigan Racing Division, while the 18-inch fifteen52 wheels are shod in Pirelli Trofeo R tires that use a specialized compound exclusive to Block.