Mazda MX-5 Superlight Version - Proceso de creaciónMore development pictures and several videos are available for download

Mazda MX-5 Superlight Version - Proceso de creación

More development pictures and several videos are available for download.

The task sounded challenging and time was short. After the decision was made to present a radical Mazda MX-5 Superlight version show car at the IAA in 2009, Peter Birtwhistle had only three months to complete it. He quickly formed a five-person team – including Hasip Girgin, Luca Zollino, Nigel Ratcliffe, Maria Greger and Luciana Silvares – which began by designing the cockpit.

There was not enough time for small-scale modelling. The designers put their ideas to paper, decided which were best, then modelled these directly onto a full-scale clay model. The cockpit was created together with the interior door braces. All components were then digitalized. This data was sent to an external studio for prototype build, where the parts of fibreglass-reinforced plastic and carbon fibre were made and later fitted. This method was also used to create the centre console with gear shift lever and hand brake.

Parallel to this, a production MX-5 Roadster with an MZR 1.8-litre powertrain was stripped of all components that would later be replaced. Under the leadership of Mazda’s design team and chassis engineers, a drivable “blank” of the MX-5 Superlight version was created that weighed well under 1,000 kg, while respecting the original roadster’s ideal 50/50 weight distribution. Mazda test drivers then drove the roadster around a closed track with experts from Bilstein® and Eibach®, in order to ascertain the feasibility of the project.

The results amazed even the most experienced engineers: with hardly any re-working, the “light” MX-5 version was an easy-to-control, safe-driving roadster that displayed agility, great driving dynamics and acoustical appeal.

Final assembly began with painting the body in white colour, and simply polishing the original MX-5 aluminium bonnet. Then the racing seats, steering wheel, gear shift lever and hand brake were upholstered in leather and installed in the show car. This was followed by the installation of all previously-built carbon fibre components. And at the end, Mazda designers installed the centre console, the dashboard and instruments, seatbelts and roll-over bars.

Weight Saving Measures in Detail

Less is more! This was the formal process that Mazda designers followed when building the MX-5 Lightweight version at Mazda R+D studios in Oberursel, Germany. All components that were not absolutely required for driving were put on the scales. Safety components were left untouched. Weight savings, by either elimination or replacement, were undertaken on the following components:

Windshield with frame and wipers

Retractable soft top and folding frame

Side windows including window openers

Outer door handles and side mirrors

Audio system

Interior trim, rugs and sound insulation

Production-model seats

Air conditioning system, heat exchanger and ventilation system

Dashboard frame

Centre console

Gear shift lever

Hand brake lever

Armrest between the seats

More development pictures and several videos are available for download.