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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.

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).

2015 Fisker-Galpin Rocket Quick Spin [w/video]

There is no shortage of fast Mustangs these days. Roush and Saleen will tune your ordinary 'Stang into something really special. Ford itself offers hot coupes like the new Shelby GT350. Don't even get me started on the endless aftermarket catalogs full of bolt-on whats-its and performance upgrades. Standing out within the huge crowd of tuned Mustangs is hard to do. But you'll definitely notice this one. "I always wanted to do a Mustang," Henrik Fisker told me as we walked toward his latest creation, the Rocket, parked outside the Inn at Spanish Bay in Pebble Beach, CA. The man knows a thing or two about design, after all. He penned the BMW Z8, as well as the Aston Martin DB9 and V8 Vantage. But this Rocket is, well, ugly. The rear end isn't totally terrible, and those 21-inch wheels are sort of cool, but taken as a whole, it looks like it swallowed something it doesn't like the taste of. But beauty is in the eye of the beholder – or perhaps, the creator – so we'll let Mr. Fisker explain why the car looks the way it does. See the video below for his brief design walkaround. If you can get past the looks, there's a world of performance to unleash, thanks to the boys at Galpin Auto Sports – the same folks responsible for the GTR1 I drove last year. The Mustang's 5.0-liter V8 gets a 2.9-liter Whipple supercharger that improves output to 725 horsepower (the torque figure isn't available), and the car's suspension has been thoroughly reworked to help put all that grunt to the ground. It's very good, yet very familiar. Let me explain. Driving Notes Like the stock Mustang, it's really easy to drive. The car fires up with a growl, you move the shifter into first gear, and the action of engagement is as solid as it is in the normal 5.0-liter car. Both the clutch and throttle have a progressive action, so it's super easy to launch the Rocket (sorry). Once you get going, there's a ton of power to unleash. It doesn't smack you in the face right up front, though – the power delivery is smooth and linear. Easy to manage, too, thanks to that slick six-speed manual transmission. Credit Ford (and Getrag) for making a manual that's able to handle so much extra grunt. That said, the Rocket feels like your typical fast Mustang. It goes like hell in a straight line and there isn't a ton of steering feel. Galpin retuned the electronic power-assisted steering, but it's still too light considering the added power of the car.