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Project Ugly Horse: Part VII

Devils, Details and Weight Reduction
There are many things I could call this exercise. A party is not one of them.
I've spent three days crammed in the axle well of this 1989 Mustang with nothing to keep me company beyond a trouble light, a DeWalt drill on the very last of its legs and billion razor sharp, red hot slivers of metal with an affinity for my most sensitive of regions. My joints are raw from crawling around on the concrete. I'm half deaf from the shriek of the spot weld cutter and the boom of the cold chisel and hammer.

2015 Ford F-150 pricing announced, aluminum-bodied truck up just $395

The eagerly anticipated Ford F-150 has had its 2015 pricing announced, adding only a small amount to the pickup's total cost, despite its weight-saving aluminum body. The XL and XLT entry level models only see a $395 boost over the heavier, current-generation, 2014 truck.
The XL starts at $26,615 while the XLT rings up at $31,890. The increase for Lariat is up a similarly negligible $895, to $39,880. Going up the ladder, meanwhile, the leather-intensive King Ranch sees the biggest jump of the F-150 family, with prices increasing $3,515, to $49,460. Finally, picking up the top-end Platinum trim will cost an extra $3,055, with prices starting at $52,155.
The higher prices are being blamed not only on the aluminum bodies, which trim up to 700 pounds of body fat, but on increased levels of standard equipment. While we were expecting a price hike, the fact that the 2015 F-150's volume trims - Ford spokesman Mike Levine told Reuters that the XL and XLT alone cover 70 percent of F-150 sales - have had less than a $400 increase is hugely impressive.

Shelby GT350R offers first mass-produced carbon fiber wheels

In the world of race engineering, reducing total weight is good, but reducing unsprung weight is flippin' fantastic. That's the reason Ford is pushing the envelope in terms of technology for the Shelby GT350R's wheels. Joining the likes of Koenigsegg in the offering, Ford has teamed with Australian outfit Carbon Revolution to produce the CF rollers en masse for the first time. Destined for the hubs of the new Shelby GT350R, the new hoops weigh just 18 pounds each, versus the 33-lbs weight of a similar aluminum wheel. On top of slashing up to 60 pounds in unsprung weight, there's such a reduction in rotational inertia – 40 percent, versus aluminum wheels – that Ford actually has to recalibrate the magnetic ride control system and springs. Thanks to, we're guessing, scenes of crashed Formula One cars disintegrating and spewing shards of carbon fiber all over the track, Ford seems quite keen to do away with the idea that CF is strong, but brittle. The company conducted extensive shock testing, ramming a wheel into a curb at speed. According to the Blue Oval, the lightweight wheel allowed the suspension to respond so quickly that the impact was "greatly diminished," causing the tester to run the experiment again, thinking there'd been a mistake. After recording brake rotor temperatures of 900 degrees Celsius (over 1,650 degrees Fahrenheit, or well past the point that aluminum or magnesium would melt) during testing, Ford and Carbon Revolution actually redesigned the wheels to "a thermal standard more suitable for motorsports," by adding an "incredibly thin, nearly diamond-hard coating that reliably shields the resin from heat." The same process was used to protect engine turbine blades on the Space Shuttle. While the work by Ford and Carbon Revolution should make GT350R customers excited, the work being done here could have serious implications for performance cars in the future. That's the real takeaway here, and is something that should leave fans of all performance vehicles excited.