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How Ford secretly used customers to test its aluminum F-150 [w/video]

Automakers getting clever about disguising development vehicles isn't anything new. Between mules wearing the sheetmetal of other cars and prototypes decked out in as much camouflage as is practical, automakers know how to make it very difficult for the general public to get an exact idea of what kind of vehicle is in development. Ford, though, is rapidly becoming the master.
We knew that the Blue Oval originally tested the durability of the aluminum construction being used for the 2015 F-150 by building an all-aluminum 2014 truck and entering it in the Baja 1000 off-road race. That's no longer a secret. What we didn't know, though, is that the aluminum development dates back to before even that, and that some of the people in question had no idea what it was they were working with.
Ford says this is the first time prototypes have ever been handed over to the public.

Ford F-150 could be affected by tornado-damaged supplier in S.C.

The disruption caused by a tornado that severely damaged a South Carolina auto-parts plant and killed a contract security guard last week could be felt by more automakers than just Ford and affect more than just its best-selling F-Series pickup, which is due for an update. And there’s still no estimate for when operations might resume at the plant. The Detroit Free Press reports that the BorgWarner plant in Seneca, near Greenville, makes transfer cases for F-150 and Super Duty pickups, the Ford Explorer and Expedition, Transit cargo vans, and Lincoln Navigator and Aviator SUVs. ItÂ’s also a supplier for the Ram 1500 and Toyota Tundra trucks. Transfer cases shift power from the transmission to the front and rear axles in four-wheel-drive vehicles. BorgWarner says it still has no update for when it might partially or fully resume operations. The tornado that ripped through the area in the western part of the state on April 13 tore the roof, walls and signage off the factory and killed a 77-year-old contract worker when the security building he was sheltering in collapsed. Only four or five others were inside the plant, which has been idled because of the coronavirus outbreak, when the tornado struck. In an SEC filing on Friday, Ford said it has sent employees to the site to help BorgWarner and assess the damage to FordÂ’s tooling. “Initial assessments indicate that the Ford tooling was not materially damaged in this incident,” Ford said in the filing. “We do not have sufficient information to estimate when the facility will be back on-line or whether or the extent to which this incident will impact our plans to resume production of four-wheel drive and all-wheel drive vehicles.” A Fiat Chrysler spokeswoman also told the Freep the company was working with BorgWarner on recovery plans. A Toyota spokesman told Autoblog that "we are collaborating with BorgWarner to help restore production for transfer cases for Tundra assembly. We are confident that theyÂ’ll fully recover over time." Like other automakers, Ford shut down production at its U.S. plants last month as a precaution against the coronavirus pandemic. But Ford hasnÂ’t yet said when it plans to reopen its factories. FCA is targeting May 4 to resume production. Models like the F-150 and Lincoln Navigator are major sources of profit for Ford, which estimated it lost $2 billion in the first quarter.

How the 2015 Ford Mustang will save your knees

The 2015 Mustang is one of the most hotly anticipated vehicles of the moment, and Ford continues to leak out interesting little details about its newest pony car. The latest info doesn't have anything to do with its quarter-mile time or handling, but if any of that goes drastically wrong, the innovative new glovebox-mounted airbag may prevent passengers from knee injuries.
All variants of the 2015 Mustang get the active knee airbag as standard, and it's the first vehicle in Ford's lineup to receive the system. The setup is actually quite simple and ingenious. The glovebox is made from a plastic outer panel that is attached to the inner door. Sandwiched between them is this new injection-molded plastic bladder that folds flat when in use. If the passenger-side airbag deploys, the system springs into action to act as a cushion for your knees. Compared to a traditional knee airbag that has to fully inflate, this arrangement is 65 percent lighter and can use a 75 percent smaller inflator. It's also basically invisible when you look at the glovebox door.
Ford spokesperson Ed Saenz declined to tell Autoblog whether the system will appear in other vehicles in the Blue Oval's lineup but said, "We're considering other applications." Provided it's effective, the approach seems too simple not to make its way to other products. Scroll down to watch a video showing how the glovebox-mounted knee airbag works.