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Home , Concept car, Ford GT, Ford GT40, Sports car, Supercar

dro Hy MORE ame as the foundation of ame. s “dream team” of designers and engineers are T THE ONE: A Blast from the Past ord’ s design team, working closely with extruder s design team, working closely extruded aluminum space fr its legendary redesigned and re-engineered 2005 Ford engine pro- 5.4-liter V-8 The supercharged MOD GT. of torque. duces 550 horsepower and 500 foot-pounds F pioneering advanced for the GT program. pioneering advanced ve raised aluminum to a new threshold. raised ve ord’ High-Powered Design Revs Up Excitement for Nostalgic High-Powered Design Revs Up Standards and GT Racer, Sets Advanced Technology Makes Automotive History Ford’s GT concept at From the introduction of the Ford to its production line debut in 2003, centennial celebration design engineers in 2004, Ford flagship brand as Ford’s ha F Aluminum North America, has developed an all-new Aluminum North America, has developed AND BUIL WITH EXTRUDED ALUMINUM SUPERCAR WITH EXTRUDED ARE DESIGNED ARE DESIGNED Ford GT Supercar with Extruded Aluminum Space Frame with Extruded Aluminum Ford GT Supercar GT’s extruded aluminum space frame makes history. FORD GT HOW FRAME REVOLUTIONIZES SPACE SPORTS The new GT, though it has every bit of its namesake’s sleek, racy look, features an aluminum extruded space frame. The all- extruded space frame. look, features an aluminum sleek, racy bit of its namesake’s it has every though The new GT, in the 1960s, uses extrusions to connect four corner castings to one behind heyday aluminum , unheard of in the GT’s welded fr the passenger compartment, creating a rigid, strong and lightweight ALUMINUM EXTRUDERS847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. Photos: © . Used with the permission of Ford Motor Company.

ALUMINUM EXTRUSION SHOWCASE FORD GT SUPERCAR—page 1 ver- MORE e us the GT40” campaign, sparking an o e us the GT40” campaign, sparking -first aluminum shim-nut system to attach and locate -first aluminum shim-nut system THE ONE: A Blast from the Past editors launched a “Giv eloped an industry Motor Trend o meet performance targets for static and dynamic body stiffness, the team created o meet performance targets for veiled, veiled, as un y 90 percent. T COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 s original design. ’ EXTRUDERS ype requirements b Ford GT Supercar with Extruded Aluminum Space Frame with Extruded Aluminum Ford GT Supercar Computer modeling was used during chassis and body development and crash testing to shorten the timeframe, cutting testing to shorten the timeframe, and crash and body development used during chassis Computer modeling was protot When the GT40 w engineering team employed put the GT back into production. The Ford management to Ford whelming reader response urging production in a record-breaking 12 concept car to market the GT from to transform unique technologies and processes forged a GT production car that retains 98 percent of between designers and engineers months. Unprecedented teamwork the concept car new joining and assembling technologies, and dev new joining and assembling technologies, body panels in proper position relative to the extruded space frame. relative body panels in proper position From concept car to market: Unprecedented teamwork between Ford designers, engineers and Hydro Aluminum’s extruders make the new GT a reality in teamwork between Ford designers, engineers and Hydro Aluminum’s From concept car to market: Unprecedented record-breaking time. ALUMINUM Photos: © Ford Motor Company. Used with the permission of Ford Motor Company.

ALUMINUM EXTRUSION SHOWCASE FORD GT SUPERCAR—page 2 - MORE ation between ,” explains Adrian Elliott, ,” y y and die longevit ystems Supervisor agrees: “We worked close- worked ystems Supervisor agrees: “We THE ONE: A Blast from the Past ord Research & Advanced Engineering. “Extrusions provide a Engineering. “Extrusions provide & Advanced ord Research ’s ability to meet design tolerance and material property tar- and material property design tolerance to meet ability ’s ord GT Chassis S , optimizing part stabilit s unique extrusion designs resulted from a close collabor s unique extrusion designs resulted Advanced Body Construction Group Leader, Manufacturing & Processes Body Construction Group Leader, Advanced Department at F and facilitat- clean and open design, allowing access to all trim and hardware, pre-production ing easy component change and part modifications during the build.” The aluminum space frame chassis includes: 35 extrusions, 30 of which were chassis includes: 35 extrusions, frame The aluminum space complex castings; aluminum panels; five multiple stamped for Ford; developed as the corners and serve formed castings, which anchor and four semi-solid The chassis features for a double wishbone suspension. mounting points spring-damper units to extruded control arms and coil-over unequal-length sup- extrusions structurally low profile. In addition, bolt-on accommodate its into the bumper assembly. compartment and are integrated port the engine aluminum. The rear sport bar is also extruded and extruder is critical, particularly regard “The relationship between designer ing the extruder gets,” according to Matt Zaluzec, Ford’s Manager of Materials Research and Manager of Materials Research Ford’s according to Matt Zaluzec, gets,” Engineering. Advanced Huibert Mees, F thick- tighter specifications for wall to develop ly with our aluminum suppliers ensure proper fit and finish for the final product.” and twist, to ness tolerance The GT’ Ford’s team and Hydro’s extruders. They worked extensively to analyze specs, to analyze extensively extruders. They worked team and Hydro’s Ford’s dies to meet profile shape or thickness fine-tune modifications, and adapt changes and welding heat requirements. that allows a bal- a design critical to achieve “The working relationship was anced flow Advanced extrusion technologies are key to the Ford GT achieving high-performance supercar status. COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 EXTRUDERS Ford GT Supercar with Extruded Aluminum Space Frame with Extruded Aluminum Ford GT Supercar ALUMINUM Photos: © Ford Motor Company. Used with the permission of Ford Motor Company.

ALUMINUM EXTRUSION SHOWCASE FORD GT SUPERCAR—page 3 MORE -welded Extruded aluminum crush rails absorb energy, protecting passengers from crash forces. - viding 300 pounds of down antages of ” Elliott notes. Front and rear extruded ” Elliott notes. Front and rear . ash, enturi tunnel, pro -car v ve been achieved without been achieved ve THE ONE: A Blast from the Past ame rigidity was critical: “Extrusions can be designed was ame rigidity , and under ” Elliott also touts the adv Mees points out the key role aluminum extrusions play in extrusions play role aluminum the key Mees points out “Extrusions are phenomenon back to the road: bringing the GT of the visual design. Many vehicle’s into the easily integrated enhance the designed with visual details that extrusions are aluminum extrusions of the Many appearance. aggressive car’s through the rear passenger compartment and are seen in the for world- torsional stiffness targets Mees set aggressive deck.” to vehicle lightweight a class body control, while maintaining targets. reach performance and handling Space fr performance, allowing individual structural optimum to provide thickness adjustments to meet bending stiffness require- wall in absorbing effective ments. The extrusions are particularly energy during a cr easily removing are bolted to the frame, aluminum crush rails impact. in case of a low-speed atios on a production car ation. ag r , rear -dr —one of the lowest lift COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 - formed aluminum outer body panels, roll-bonded aluminum floor panels, a friction-stir -plastic formed aluminum outer EXTRUDERS , side skirts, completely enclosed underbody , side skirts, completely enclosed y reducing fuel consumption and emissions gener y reducing fuel consumption and aditional body structure. Once tooling is complete, long extrusion lengths are easily made at mod aditional body structure. Once tooling is complete, long extrusion Ford GT Supercar with Extruded Aluminum Space Frame with Extruded Aluminum Ford GT Supercar force at 130 miles per hour The GT uses super weight, vehicle to reduce overall “The use of aluminum throughout the GT helped observes, Zaluzec thereb targets were set for weight and perform- “Aggressive lightweight aluminum components in the GT: not ha ance, directly influencing fuel consumption. These targets could using extrusions.” “The tooling required to produce alu- says, Zaluzec is an important consideration. Cost effectiveness to the stamping tooling of a more especially compared minum extrusions is extremely inexpensive, tr center The aerodynamic package includes a front engine cover. tunnel, a capless fuel filler system, and a polished aluminum splitter Extrusion cross-sections are tightly tailored to the applications, minimizing material cost. erate that, although vehicle to producing a low-volume are key and weight. All these characteristics waste targets.” and investment price class, must meet stringent cost it competes in an expensive The rigid extruded aluminum space frame meets tight specifications for The rigid extruded aluminum space frame handling, weight and safety considerations. ALUMINUM Photos: © Ford Motor Company. Used with the permission of Ford Motor Company.

ALUMINUM EXTRUSION SHOWCASE FORD GT SUPERCAR—page 4 MORE ” ve specific performance. ve ation. ” Mees says, “Aluminum extrusions offer one extrusions offer “Aluminum ” Mees says, On the road again: The GT supercar combines winning technology, design and appeal. e weight and impro v Hydroforming will be used to optimize profile shape, will be used to optimize Hydroforming to assist in this integr sa These Ford experts assess aluminum extrusion’s experts assess aluminum These Ford of of the future: “With the cost potential for cars demands for more fuel-efficient steel rising and aluminum will continue to play increasing, vehicles reducing vehicle role in strategic an important weight, options for getting alu- of the lowest investment minum into the vehicle.” dominant in the Elliott adds, “Extrusions will remain At investment. arena due to low tooling low-volume be use of extrusions may selective higher volumes, unibody architectures to into conventional integrated THE ONE: A Blast from the Past © Copyright 2005, Aluminum Extruders Council. COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 ound for pound, aluminum is stronger than steel, and as . P EXTRUDERS en the proper design and construction methods.” Ford GT Supercar with Extruded Aluminum Space Frame with Extruded Aluminum Ford GT Supercar For more information on aluminum extruders, request your free copy of the AEC Buyers Guide at [email protected]. Buyers of the AEC free copy more information on aluminum extruders, request your For Ultimately, says Zaluzec, “The flexibility in design of the extrusion cross-sections meets our various design demands. We our various in design of the extrusion cross-sections meets “The flexibility Zaluzec, says Ultimately, Elliott weight to a minimum.” overall to the demands of each component, to keep thickness exactly were able to tailor wall performance. each individual extrusion allowed optimum joint and sub-assembly in achieved agrees, “The complexity requirements.” and investment for sports cars, particularly , due to performance Extrusions are becoming the norm components more extruded aluminum and aluminum-alloy designs are incorporating new automotive Industrywide, many cylinder heads, bumpers, and side impact beams. Aluminum blocks, radiators, suspensions, chassis, engine into frames, parts to key extruders are at the forefront of this trend, supplying using significant Automobiles for newly designed vehicles. automakers aluminum design elements include: the 2005 DB9; the 2005 the 2005 BMW 6 Series; the 2005 ; the 2005 Enjoy; 612 Scaglietti; and Legacy; the 2005 Subaru WRX STi; the the Jaguar XJ engineers attest, “...aluminum meets the same federal crash standards as crash engineers attest, “...aluminum meets the same federal steel, giv Only 1,500 Ford GT supercars will be produced each year. Only 1,500 Ford GT supercars will be produced ALUMINUM Photos: © Ford Motor Company. Used with the permission of Ford Motor Company.

ALUMINUM EXTRUSION SHOWCASE FORD GT SUPERCAR—page 5

- ehi MORE —the first y Jay Leno and Jay acing car of its da Tonight Show’s e dubbed it a retro-techno v aight at Le Mans. ” They’v . y as the fastest sports r THE ONE: A Blast from the Past ype at the 2004 Super Bowl. It’s been grabbing inter- been grabbing ype at the 2004 Super Bowl. It’s acing icon. It w ceed 200 mph on the Mulsanne str ceed 200 mph on the Mulsanne cle—in essence a remake of the nostalgic vehicle for today’s market. market. for today’s of the nostalgic vehicle cle—in essence a remake NASCAR hot shot Matt Kenseth parking this supercar in their own drive- parking hot shot Matt Kenseth NASCAR ways. sight a rare that is sure to be production vehicle Though it is a low-volume and billing it as the 2005 GT “The One,” is calling the on the road, Ford “pace car for an entire compan In the 1960s, the line collectively known as GT40 became a 20th collectively In the 1960s, the sports car line century r to ex Now, the legend is reaching a new echelon with production of the 2005 the legend is reaching a new echelon with production of Now, and most wave The $140,000 sports car is launching the biggest GT. Ford its television It made history. rollout of new products in Ford’s aggressive debut in a swirl of h since, with celebs like national headlines ever Ford GT Supercar with Extruded Aluminum Space Frame with Extruded Aluminum Ford GT Supercar “THE ONE”: A “THE ONE”: BLASTFAST FROM AND THE DRIVE FURIOUS PAST INTO THE STEERS FUTURE A Jay Leno gives his new FORD GT a thumbs up. At 200+ mph, Leno proclaims his GT Supercar is “faster than fast!” ALUMINUM EXTRUDERS847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. Photos courtesy of Willy T. Ribbs and Matt Kenseth; Used with permission. Photos: © Ford Motor Company. Used with the permission of Ford Motor Company.

ALUMINUM EXTRUSION SHOWCASE FORD GT SUPERCAR—page 6 MORE THE ONE: A Blast from the Past . ear e y . The Ford GT40s of the 1960s, developed on the orders of Henry Ford II, challenged Ferrari for road-racing II, challenged Ferrari orders of Henry Ford on the GT40s of the 1960s, developed The Ford Historic first place win by Mark IV in the . Ford wins at Le Mans for American Mark IV in the 24 Hours of Le Mans. Ford Shelby Historic first place win by Ford GT Supercar with Extruded Aluminum Space Frame with Extruded Aluminum Ford GT Supercar 1968: the fourth consecutiv 1960s: A Racing Icon is Born A Racing Icon GT40s crossed the finish line 1-2-3 at the 24 Hours The challenge turned into a rout in 1966, when Ford supremacy. race debut a Next, cars. sports Championship for Manufacturer’s earn the World that helped Ford of LeMans—wins LeMans wins. Continental and continued at Nurburgring; first place at Daytona “The Ford GT was built by people who love great cars, and Ford Motor Company is full of people who share the same is full of people who share the Motor Company cars, and Ford great people who love built by GT was “The Ford for the Ford manager said Carter Balkcon, marketing SUVs and trucks,” cars, on our high volume passion but work our It’s in ‘The One’. captured we think we have the spirit and that’s pace car, the company’s it’s why “That’s GT. and on top as the industry leader rebound from tough times to back Ford’s and represents big buzz of excitement pace setter.” of two a glimpse into the future through the eyes and history, moments in the GT’s Here is a look at memorable guys who casually Kenseth, hot star, Ribbs and today’s Willy T. car drivers race greats, then and now: Ford racing about winning fast at high speeds. They know their cars, and they know all course and off the race life on navigate and furiously ALUMINUM EXTRUDERS847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. Photos courtesy of Willy T. Ribbs and Matt Kenseth; Used with permission. Photos: © Ford Motor Company. Used with the permission of Ford Motor Company.

ALUMINUM EXTRUSION SHOWCASE FORD GT SUPERCAR—page 7 MORE ys until the with Jay Leno, HBO special with Bryant Leno, with Jay s farm in San Jose, California, sa s farm in San Jose, California, . Currently, he’s starring in a pilot remake of starring in a pilot remake he’s . Currently, Tonight Show THE ONE: A Blast from the Past American Reel actors on his family’ ord in Europe. One of Ribbs’ most notable sponsors was entertainer Bill entertainer notable sponsors was ord in Europe. One of Ribbs’ most ormula F SCAR, and F President Dan Quayle, Paul Newman, Clint Eastwood, Jay Leno, Colin Powell, and many others. and many Colin Powell, Leno, Jay Newman, Clint Eastwood, Paul President Dan Quayle, Ribbs, who started driving tr changed all that, The GT sedans.” cars as “trucky-looking thought of Ford he always GT, Ford Corvette.” behind the of a sporty I was “Back then, I felt like he recalls and says, When Willy T. Ribbs entered the racing scene in 1977 driving Ford Formula Cars, he remembers Formula in 1977 driving Ford scene racing Ribbs entered the When Willy T. An auto-racing throughout the industry. name sporty made the Ford GT40 Ford fondly how the in and race to qualify the first African American becoming sports history by pioneer who made Ford him to drive drafted began when Ford career 500, Ribbs’ 25-year the Indianapolis cars in Europe. Formula and Jack Roush for such winning teams as , at the top of his field, racing Ribbs was Car, CART/Indy in such series as SCCA Trans-Am, He won more than 40 races Derek Walker. NA Cosby, and his career has crossed interesting paths with such notables as Muhammed Ali, Vice has crossed interesting paths with such notables as Muhammed and his career Cosby, , and Columbia Pictures and actor Michael Douglas purchased the rights to Ribbs’ life story for a future , and Columbia Pictures and actor Michael Douglas purchased . EXTRUDERS IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, Unbrakeable , Ford GT Supercar with Extruded Aluminum Space Frame with Extruded Aluminum Ford GT Supercar Racing pioneer Willy T. Ribbs says, "The GT40 changed Ford's image forever." Gumbel, MTV’s “True Life: I drive race cars” and the ESPN special, “A Forgotten Race.” Ribbs’ acting debut was opposite David Ribbs’ acting debut was Race.” Forgotten the ESPN special, “A cars” and race Life: I drive “True Gumbel, MTV’s motion picture in the major and Mariel Hemmingway Caradine movie. Ribbs has appeared on several television programs including the television programs Ribbs has appeared on several movie. Dolls A Blast from the Past: Willy T. Ribbs T. Willy from the Past: A Blast In "race-talk," Ribbs acknowledges the lighter feel of those aluminum extruded vehicles, which he test-drove during practices. test-drove which he the lighter feel of those aluminum extruded vehicles, Ribbs acknowledges In "race-talk," impact for his crew and supporting mechanics on call. construction made a significant is where the car’s In the pits, he says, whip out a new mold and the crews could framing, but with the aluminum practice, a lot of cars during “I kind of wrecked 100 or so of those body molds keep “We’d recalls Ribbs. in no time. It made a huge difference,” me back on the track have around just for that.” supercar into the realm of a Le Mans-worthy just a , beyond the GT is one American car that goes way Ribbs says of its predecessor.” that “is worthy is in the works on his life An autobiography coverage. as a commentator for Ribbs, 49, often serves These days, story ALUMINUM Photos courtesy of Willy T. Ribbs and Matt Kenseth; Used with permission. Photos: © Ford Motor Company. Used with the permission of Ford Motor Company.

ALUMINUM EXTRUSION SHOWCASE FORD GT SUPERCAR—page 8 THE ONE: A Blast from the Past ace against a enture. , in a r , AirV The aerospace-inspired 2005 2004: GT supercar wins at speeds over Ford 170 miles per hour CAP 232 aerobatic plane at the world's largest air show A concept version of the Ford GT is unveiled at the 2002 North American International Auto at the 2002 North GT is unveiled of the Ford A concept version ord GT concept vehicle is featured at 2003 North American International Auto Show. The Show. International Auto is featured at 2003 North American ord GT concept vehicle The first production-level cars are unveiled at Ford’s Centennial celebration in June 2003. Centennial celebration at Ford’s cars are unveiled The first production-level 2002: 2 Fast, 2 Furious: Ford GT Back on Track Back on Track GT Ford 2 Furious: 2 Fast, Show in Detroit. That spring, Ford approves the car for production. Ford’s “Dream Team” begins “Dream Team” production. Ford’s the car for approves That spring, Ford Show in Detroit. in a record-breaking 12 months. work, bringing concept to market 2003: Updated F Motor Cars of Exceptional summer at the Christie's Auction is underscored later that desirability car’s auc- is sold for $500,000 (plus GTs first Ford of the production line’s Beach, CA, when one at Pebble to charities. tion fees), with net proceeds going Ford GT Supercar with Extruded Aluminum Space Frame with Extruded Aluminum Ford GT Supercar ALUMINUM EXTRUDERS847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. Photos courtesy of Willy T. Ribbs and Matt Kenseth; Used with permission. Photos: © Ford Motor Company. Used with the permission of Ford Motor Company.

ALUMINUM EXTRUSION SHOWCASE FORD GT SUPERCAR—page 9 e this is Big Win: The GT leads the list of prizes for Kenseth's racing victories. © Copyright 2005, Aluminum Extruders Council. . THE ONE: A Blast from the Past , the video game, you'll run into Matt Kenseth, the 20- run into Matt Kenseth, you'll , the video game, es per cylinder alv , Kenseth commands the wheel of his Ford GT, a gift from The Ford Motor a gift from The Ford GT, commands the wheel of his Ford , Kenseth ou pick up speed. The aerodynamics of a high-performance machine lik ou pick up speed. The aerodynamics -8 with four v NASCAR 2005: Chase for the Cup NASCAR 2005: SCAR experience as he tackled the All-Pro Series. In Back to the Future: 2005 the Future: Back to Matt Kenseth something kid who was a natural winner from the day he put his key in the ignition. The 2003 in the ignition. The he put his key day winner from the a natural was something kid who is the Racing for Roush Ford 17 DEWALT No. the Winston Cup champion who drives NASCAR car fanatic in real life. In the video game, countdown and a muscle in the game’s driver first Ford a super- a 550-hp monster powered by GT, streets in his sweet Ford cruises the city Kenseth charged V On his home turf before weeks lead for a record 33 straight when he held the Winston Cup points Company ed up to the Busch Series in 1997, he was used to hanging out in the ed up to the Busch Series in 1997, he was ord GT: “This is a true race car. We’re right on the ground, which is where you need to be. The right on the ground, which is where you We’re car. “This is a true race ord GT: v enseth mo ys about the F s top-10 finishes as a rookie and then scored seven circle. The winning continued as Kenseth ’ Ford GT Supercar with Extruded Aluminum Space Frame with Extruded Aluminum Ford GT Supercar enseth sa "This is a true race car," proclaims NASCAR superstar Matt Kenseth. If you have an application story to share, email the Showcase staff at: [email protected] an application story have If you ultimately which was GT, a Ford to $9 million and the keys crowned the Winston Cup champion. His winnings: a cool being late in 2004. to him delivered for winning the championship.” received things that I’ve one of the neatest “That’s Kenseth, says cool,” “It’s K gauges are laid out perfectly, and the are deep and the gearshift is high. The engine sounds great, and I like how you gearshift is high. The engine sounds great, and I like and the seats are deep and the gauges are laid out perfectly, ground as y can feel the car flatten to the went on to earn his first three Busch wins a year later taking 17 top-five and 23 top-10 finishes, and later taking 17 top-five went on to earn his first three Busch wins a year once and for all that there is no sophomore slump. proving winner important. The pickup is just like a race car—it eases from first to third no problem, and it takes the turns well." the turns eases from first to third no problem, and it takes car—it race a important. The pickup is just like started racing The Wisconsin native it took two races. Kenseth, For to earn their first victory. years it takes some racers, For By age 23, Kenseth in history. Challenge Series winner ARTGO at age 16. By the time he turned 19, he became the youngest had already gotten his first NA By the time K ALUMINUM EXTRUDERS847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. Photos courtesy of Willy T. Ribbs and Matt Kenseth; Used with permission. Photos: © Ford Motor Company. Used with the permission of Ford Motor Company.

ALUMINUM EXTRUSION SHOWCASE FORD GT SUPERCAR—page 10