Aluminum extrusions from Hydro Aluminum North America are key elements of this exciting new vehicle. Aluminum was chosen for its strength, light weight and cost effectiveness – and it fit the cutting-edge image that Ford wanted. Hydro was selected because of the company’s extensive transportation experience.

Hydro is supplying 35 individual extrusion profiles, 30 of which were developed specifically for Ford. Extrusions connect four corner castings and one behind the passenger compartment to create a welded frame that is lightweight, yet rigid and strong. Rocker panel extrusions are also used.

Bolt-on extrusions add structural support to the engine compartment and are integrated into the bumper assembly. Each GT is assembled using robotic welding and friction stir welding. And the amazing part is that all of this was brought to market in record time – only 12 months from initial design to prototype production.

The 2005 Ford GT went on sale in spring 2004. Ford will build approximately 1,500 of the supercars a year. If you get the chance, check out the door handle. It’s one of the aluminum frame extrusions serving a dual purpose. Every time you open the door, you’ll get a feel for the high-tech metal that plays such an important role in this historic vehicle.