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Lightweighting the F-150 – the production story

Simon Duval Smith looks at the manufacturing challenges behind switching from steel to aluminium

Going against much of conventional wisdom, and ignoring the old adage of ‘if it ain’t broke, don’t fix it’, Ford is taking more than 700lbs out of its best-selling vehicle, the F-150, using radical aluminium body construction. The OEM boasts that the F-150 - one of which sold every 41 seconds during 2013, is almost entirely made from lightweight aluminium.

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