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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.

Ford Transit production fires up, American Pickers among first takers

Not long ago, the History Channel showed a seemingly unending stream of World War II documentaries, but it made a switch a few years ago to include an increasing mix of 'reality' programming. American Pickers was one of the early attempts at this new formula, with cameras following hosts Mike Wolfe and Frank Fritz around the country in a Mercedes-Benz Sprinter as they tracked down collectibles and "rusty gold" for their Iowa shop, Antique Archeology. The show has since gone on to become one of the channel's most popular programs.
Starting in the new episode airing tonight, the affable hosts will swap their Benz for a 2015 Ford Transit, a nicely timed bit of marketing to coincide with the launch of the model's assembly at the Blue Oval's Kansas City Assembly Plant, which also kicks off this week. Ford is touting 2,000 new jobs created as part of its $1.1-billion investment in the plant.
No strangers to product placement, the guys from American Pickers say their switch away from the Sprinter is because they wanted to balance cargo capacity and fuel economy to make the most of their cross-country jaunts. They opted for the largest Transit available with a long wheelbase, extended body and high roof, giving them 487 cubic feet of cargo room. Hauling power comes from a 3.2-liter, five-cylinder diesel engine with 190 horsepower and 346 pound-feet of torque and a six-speed automatic transmission with rear-wheel drive. Fittingly, the van wears the same Antique Archaeology logo over white paint as their old Sprinter.

How Ford plans to handle insurance and repair questions surrounding new aluminum-bodied F-150

Building a car out of aluminum has a number of benefits - the lighter weight allows the vehicle to be more agile, more fuel efficient, make better use of its power and be more resistant to dings and dents. The downside to the advanced construction, though, is that repairs are both challenging and expensive. That's troubling for the new, aluminum-bodied Ford F-150, because it's kind of made a name for itself as a rugged, durable work vehicle.
How will the legions of Ford buyers cope when it comes time to insure and repair their new trucks? Well, according to Ford, it's expecting a ten-percent jump in insurance costs for the aluminum-bodied F-150, although Ford's truck marketing manager, Doug Scott, was quick to point out that the F-150 is generally cheaper to insure than its competition from Ram and General Motors. "At the end of the day, that's sort of a wash," Scott told Automotive News at last week's Detroit Auto Show. "We've spent a lot of time and feel very comfortable that that's not going to be an inhibitor."
The other issue facing Ford is the distinct lack of body shops that have the training or equipment to repair aluminum-bodied vehicles. AN cites an estimate from the Automotive Service Association claiming that of the 30,000 independent body shops in the US, less than 10 percent are able to work on aluminum.