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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.

Ford F-150 King Ranch celebrates 'history and authenticity' for 2015 [w/video]

What's life like on an authentic Texas ranch? We honestly have no idea, having never lived on such a ranch, but we imagine it requires lots of hard work, grit and determination to keep all 825,000 acres - that's larger than the state of Rhode Island - of the King Ranch in Texas under control. Indeed, a total of 350 vehicles, all of which come from Ford, we're told, are currently in use by the ranch. No wonder, then, that the collaboration between Ford and King Ranch has lasted for 15 successful years.
For 2015, in celebration of that 15th anniversary, Ford is debuting three new King Ranch models today at the Houston Livestock Show and Rodeo. The most significant is the 2015 F-150 King Ranch, which, naturally, will add unique interior and exterior bits and pieces to the new aluminum-intensive F-Series pickup. Color choices will consist of Caribou, Bronze Fire, Guard and Ruby Red Metallic Clearcoat, with a range of two-tones to go along with a monochromatic scheme in Caribou. Inside, a bespoke King Ranch interior will be swathed in Premium Mesa Brown leather.
Joining the F-150 King Ranch on dealership floors later this year will be 2015 King Ranch editions of the Super Duty pickup and Expedition fullsize SUV, all of which will offer similar levels of content. Scroll down for more details and two videos from Ford, and be sure to check out the high-res image gallery above, which was shot by the official State Photographer of Texas, Wyman Meinzer.

Experts wonder if aluminum F-150 gives Ford a real advantage

There's no doubt that Ford is taking a risk in producing the body of its upcoming new F-150 pickup truck in aluminum. What is up for debate, however, is whether aluminum was a wise risk to take in the first place. Wards Auto took the opportunity to poll some experts on the subject of aluminum versus steel in the automotive sector, with somewhat unsurprising results.
Richard Schultz, a project consultant at Ducker Worldwide, which bills itself as "a leading aluminum industry consultant (though they also deal in steels), suggests that the potential drawbacks to aluminum - higher costs, lower supply - aren't really impediments to the auto industry's increased acceptance of the lightweight metal.
Similarly, Randall Scheps, global automotive marketing director for Alcoa, a massive aluminum producer, counters claims that aluminum is less safe for vehicle occupants, suggesting that the use of aluminum can actually increase safety as it could potentially allow for larger vehicles with more crush space than steel.