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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.

Automakers' rush on aluminum may result in shortage

Aluminum is the new buzzword in the automotive industry. The latest Range Rover and Range Rover Sport both take advantage of the lightweight material to shave huge amounts of body fat (only it's called "aluminium" over there). Audi and Jaguar have been using the stuff for years in their A8 and XJ, respectively, and now, aluminum is going mainstream, arriving on the 2015 Ford F-150.
While we're excited to see aluminum make an impact outside the premium market, its widespread adoption apparently won't come without some problems, notably in terms of supply. "There isn't an automotive manufacturer that makes vehicles in North America that we're not talking to," Tom Boney, of Novelis, the largest global supplier of aluminum sheetmetal, told The Detroit News.
According to Boney, Ford's use of aluminum on such a large scale has forced auto manufacturers in "every boardroom" to reconsider their plans following the F-150's unveiling, for one simple reason: there's not exactly enough aluminum to go around, at least in the short term. The auto industry presently only accounts for six percent of the aluminum sheet produced, but as the material is adopted by more and more brands, that figure is expected to swell to 25 percent within the next six years.

Lincoln Aviator could make a comeback

The idea of Lincoln dropping its alphanumeric scheme in favor of real names was welcomed by fans of the marque and even appeared possible after the rousing reception to the Continental concept. Now, rumors suggest that the next of the luxury brand's nameplates to see a possible revival just might be the Aviator. Don't get your hopes up quite yet, though. The Truth About Cars admits that this tip comes from a second-hand source, but the person reports that Lincoln has a project codenamed Aviator as a model based on the Explorer. There's evidence to give the rumor some shaky support, though. Ford already has the trademarks for the name and AV8R. Also, an Explorer-based vehicle in 2019 is included for the brand's predictions in the recent Car Wars forecast. Autoblog reached out to company spokesperson Sam Locricchio, but he would not speculate about future products. The same source claims to The Truth About Cars that the Blue Oval might not replace the Ford Flex or Lincoln MKT when the current generations come to an end. Also, the next-gen Expedition and Navigator could use 10-speed automatics and follow the F-150 to get aluminum bodies, which is also already rumored. Although, all of this should be taken with a big grain of salt until anything more official has arrived. Lincoln spokesperson Stephane Cesareo gave The Truth About Cars no comment on the rumor, but said, "By 2020, we expect to expand the segments that we participate in by adding two new nameplates to the Lincoln brand. We have not provided any indications about the products or their names." Related Video: