Mahle | Colin Chapman Archive and Resource

Sponsor, Brands, Specialists and Suppliers: The Companies that supported the Chapman /Lotus Road & Racing Programme

Figure 1: Illustration by Hutton, Lotus 97T

Mahle

Pistons

Research finds the Jewel in the Crown

Introduction

Lotus cars sold

They were bought for their:-

Performance –road or track
Driving pleasure
Reputation and image
Aesthetics
Symbolism
Owner identification /personality extension etc.

All the above were integrated within a total framework design.

The above list is heavily dependent on a select group of components [either bought in proprietary or in house manufacture] that delivered the desired outcomes and met strict criteria.

Many of these components often contributed significantly to the overall aesthetic, many are extremely functional and beautiful in their own right .They formed part of a complementary whole.

In this series we examine:-

significant Individual components from all the marque types
Briefly explain their role /contribution /evaluation
Analysis form and function with regard to their integration, where appropriate
Provide suppliers/specialist advertising materials where appropriate

Understanding Lotus’s use of proprietary parts provides invaluable learning opportunities not just historical but right up to the present day. These lessons are not just applicable to automotive engineers/ designers but to the wider Industrial /Product Design professions.

The Skillful and creative adoption, absorption and integration of components was a powerful factor in the Chapman design methodology and contributed significantly to both competition and commercial success. It also feed his ability to mutate parts and materials to his desired ends.

The use of components is a fundamental skill of the Industrial Designer and the direct provision of added value.

The exact interpretation of sponsorship in conjunction with Lotus is difficult to establish objectively. The appearance of a sponsor’s logo on a car is not necessarily evidence of financial support. Access to historical archive and contracts is sought wherever possible but with the passage of time and for various reasons these are not always available or accessible to the public.

This series also embraces the specialist suppliers to Lotus. We are particularly interested in those suppliers and products that have a connectivity with aviation.

In constructing the historic sponsor series, the A&R looks only at the logos worn in period and assumes the company involved had no objection to Lotus promoting their products. The A&R sees much to be gained by the wider promotion of sponsors but in the event that a specific organization disapproves for any reason that article will be removed.

Sponsorship is an instrument of mutual benefit and promotion. Subscribers might like to see A&R articles on Sponsorship and Product Placement to understand the numerical / financial reach provided by sponsorship with its ability to identify and project status through identification.

The principle continues particularly with regard to education based exhibitions [see below for details]

Each of these articles is devoted to a company/ organization that is believed to have sponsored or supplied specialist items to Lotus.

The intention of each article is to: –

Explain the sponsors own history and outline their products and services – past-present and future
Explain the historical connection with Lotus and the contribution made both in competition and the production cars
To suggest how these two interlocking facets may be translated into exciting, interpretive, educational and commercial exhibitions

Subscribers might to see complementary and structured pieces to this article: –

Primary sponsors like Gold Leaf / John Player Specials
Product Placement
Separate dedicated series on engines and gearbox
Logo on Lotus
See our dedicated articles on engines used by Lotus in F1
Also the British piston and rings manufacturers in this series

Pistons definition

Reyat explains:

“It is a cylindrical plug or bucket which moves up and down in the engine cylinder.It serves the following purposes:

It serves as a movable gas tight plug to keep gases inside the cylinder
It transmits the force of the explosion to the connecting rod
It acts as a guide and bearing to the small end of connecting rod and bears the side thrust when the rod is oblique
It acts as a carrier for the piston rings

The piston looks like a bucket, which carries rings at the upper part to provide a good seal between the cylinder wall.Inside the open end, connection with the connecting rod is made with it through the gudgeon pin.

The lower part of the ring groves is known as the skirt which provides a bearing and guiding surface on contact with the cylinder wall.

The top of the piston is called the crown or head….

Pistons are made in cast iron, semi-steel or aluminium alloy. In early days, cast iron was popular employed in the engine due to their excellent wearing qualities and general suitability to manufacturer.

The question of weight reduction has led to the manufacturer of aluminium alloy pistons which are common now ….. Pistons are of different design, some have plain head, whereas the others are of convex or concave crown “

Hillier and Pittuck add:

“the crown forms the upper surface on which the gas pressure acts and the force due to this pressure is equal to the cross section area of the cylinder multiplied by the gas pressure.this force, which acts along the centre line of the cylinder, is transmitted through the structure of the piston to the gudgeon pin bosses and thence through the gudgeon pin to the connecting rod…..

The crown of the piston is directly exposed to the full heat of the burning gases during combustion. These gases are still extremely hot during the power and exhaust strokes, the piston absorbs a great deal of heat from these hot gases and will reach a very high temperature unless heat is removed from the piston quickly enough to keep its temperature within reasonable limits.

The piston can pass this heat onto the cylinder wall through the piston rings and skirt, and it can do it better if the metal of which the piston is made is a good conductor of heat……”

Mahle Company Profile /Abbreviated summary

Everything begins in 1920 in an unimposing workshop. Today you would probably call it a start-up. Hermann Mahle joins Hellmuth Hirth’s Versuchsbau as commercial manager. Soon they decide to produce light-alloy pistons for engines. Ernst Mahle follows in 1922 as developer and head of production. However, the technology is still finicky, and problems come up frequently. To keep dirt and dust out of the engine, they eventually developed air and oil filters as well. In just a few years, the company is one of the major German piston manufacturers. The two brothers become managing directors, eventually sole owners. But they are above all one thing – resourceful and persistent.

From manageable beginnings, the company has grown into an international development partner and supplier to the automotive industry, a technology driver for the mobility of tomorrow.

https://www.mahle.com/en/about-mahle/locations/germany.jsp

MAHLE Means Performance

The undisputed technology leader in the piston field. With over 95 years of rich heritage MAHLE Motorsport pistons have won championships at all levels, including Formula 1 seasons with 16 out of 18 race wins supporting six of the ten teams, nearly two decades of straight wins at Le Mans, and championships in all three top levels of NASCAR®.

In the Chapman/Lotus era the Company was identified with quality.

Figure 2: Image from the net

Lotus Connections

Slater describes the Mahle pistons in detail and is worthy of an extended quotation.

“The six Mahle aluminium pistons 86mm diameter in the EF4 and 80.6mm in the EF15 each feature three Goetze piston rings and have flat tops, pocketed to allow vale clearance.

The design of both the piston and the combustion chamber were the subject of continuing development and evolution through the life of the engines in the search for both maximum power and the most efficient lean-burn processes to meet the requirements of the 220-litre and 195 litre “fuel economy “ regulations….

The pistons also feature oil gallery circulation, with jets spraying oil onto the underside of the pistons to reduce piston crown temperatures, a design element initially borrowed from heavy diesel engines

As the maximum thermal loading of an engine is limited by what pistons, rings, valves and valve seats can withstand ,Renault ,Mahle and Goetze engineers worked together to develop materials to operate in the highest possible temperatures. This included experimental work on high temperature alloys, steels and ceramics for pistons and rings “

Figure 3: Editors sketch intended to explore the interrelationships of major design components

Renault Turbo Engines

With specification from Bamsey.

Figure 4: Editors sketch of the Renault EF 15 engine that used Mahle pistons

EF 15	EF 4
90 degree	90 degree
V6	V6
80.1 x49.4 mm /1492cc	86 x42.8mm/1492cc
2Garrett turbo chargers	2 KKK turbochargers
Aluminium block and heads	Aluminium block and heads
Nikasil wet aluminium liners	Nikasil wet aluminium liners
4 main bearings, plain	4 main bearings, plain
Steel crank , 3pins	Steel crank , 3pins
Steel conrods	Steel conrods
Mahle light alloy pistons	Mahle light alloy pistons
Goetze rings	Goetze rings
4 ohc,belt driven	4 ohc,belt driven
4 valves/cylinder,1 plug	4 valves/cylinder,1 plug
29.8 mm inlet valve 26.1mm exhaust	29.8 mm inlet valve 26.1mm exhaust
21.5 degree inclined valve angle	21.5 degree inclined valve angle
Weber injection	Kugelfischer injection
Marelli ignition	Marelli ignition
Renix engine management system
Compression ratio 7.5:1	Compression ratio 7.5:1
Maximum rpm,12000	Max rpm 11000
154kg.including turbo system ,clutch & starter	160kg including turbo system, clutch & starter

Period Address for economic geography exercise

Mahle kg

Mahle Gesellschaft MIT

Beschraentkter Haftung

Pragstr 24-46

Stuttgart

70376

Learning Opportunities

Our learning /educational opportunities are intended to be challenging thought provoking and requiring additional research and/or analysis.

These opportunities are particularly designed for a museum/education centre location where visitors would be able to enjoy access to all the structured resources available in conjunction with any concurrent exhibition.

Understanding the potential of componentry particularly proprietary items provides some of the following learning opportunities; in this instance we suggest the following might be appropriate:-

Figure 5: Editors template sketch for learning exercises

Specific to Mahle:

Be conversant with theory of heat and friction and how these forces relate to pistons especially in the Renault Turbo engine
What role does chemistry and metallurgy play in consideration of piston specification?
Using template above draw location of pistons and related components annotate describing functions
Make an annotated sketch of a typical piston indicating the forces with which it has to contend
Compare and contrast the various metals and alloys that have been used in pistons, what are the advantages and disadvantages?
What are the industrial procedure in the manufacturer of typical pistons?
Who are the world’s leaders in piston manufacturer? And what is their volume?
Study Mahle website and comment on their industrial/commercial strategy going forward, how do they see priorities and opportunities?
Mahle has a honourable record in staff welfare, explain this in Germany industrial policy context
What R&D does Mahle undertake?
Compare and contrast Mahle industrial strategy with a British equivalent from our series
What is the size and value of the industry
How has it changed? And what is its future 2020 onwards?
Discuss the relationship with a multi-national mass-production car brand/manufacturer and its links, how and why did it come into existence?

General

Use a technical dictionary where needed to define components and roles
Was there a viable alternative to the part under consideration?
Is what might it have been /cost?
Examine the suppliers/specialist advertising what does it convey? And what is its iconography?
Integrate this item with our series on the economic geography of motor sports locations and manufacturing bases
Has the component had exposure at any motor shows?
Does the company continue to supply classic/heritage parts?
What changes in technology and materials have impacted on Lotus through its history?
How does component design impact on form and function
Does the supplier/specialist have aviation links? If so what?
What is the importance of ergonomics and how does it influence modern automobile design?
Does excessive safety/ and or ergonomics impact negatively on aesthetics
What is the impact of standardization of platforms through mark ranges and indeed shared with other manufacturers? Could uniformity ultimately impact on sales even if economies of scale improved?
Enumerate Lotus bought in components
How has mass production and proprietary parts assisted the specialist car market?
Produce an engineering drawing of a selected component and consider the specification of the materials and assembly process, costs and volume
Explore an enumerate supplier/specialists components used in other Industrial Design fields
How did the supplier/specialist extract value from their sponsorship/support?
Explore Graces Guide for further background detail
Study the economic geography of the British auto industry what factors determined locations?
What have been the causes of change and circumstance that have impacted on British motor industry?
What has been the role of F1 /motor sport valley based around Bicester?
What is the importance of outsourcing to the motor industry?
Study a British car specialist like Morgan, TVR, Ginetta or Lotus where do they source parts? What are the advantages?

Exhibitions, Education, Economics and Entertainment

In the museum context the editors believe that commercial considerations are both necessary and complementary with its educational objectives.

For these reasons our suggested outline Business Plan includes provision for promoting products and services which share Chapman’s ideals of mechanical efficiency and sustainability. In addition we propose merchandising that explain and interprets the social and cultural context of Chapman’s designs in period. It’s suggested there will be catalogue for on line purchasing.

In this instance we suggest the following exhibition titles might be appropriate:-

Figure 6: Editors pencil sketch of the Renault Turbo engine

Specific:-

Mahle	Pistons	performs in heat of the race
Mahle	Pistons	Head on :Full frontal F1
Mahle	Pistons	Makes headway in F1
Mahle	Pistons	A crown indent and Entente Cordiale
Mahle	Pistons	The power behind the throne takes the Crown
Mahle	Pistons	Keeping your head when others…..
Mahle	Pistons	Crowning Glory
Mahle	Pistons	Research finds the Jewel in the Crown
Mahle	Pistons	Winning the Crown and F1 title
Mahle	Pistons	Wears the crown in the combustion chamber

General:-

Lotus Parts: Past ,Present Future
Lotus Parts: The Winning Factor
The Principle Part
Act the Part
Assign the Part
Lotus Components
Lotus Components :Parts and Parcel
Lotus Sponsors, Specialist and Suppliers:Form,Function and Forte
Lotus Components:Parts and Partiality
Lotus Aesthetics : With little to spare
Lotus Cars: Spare and Slender
Product launch with title of dedicated specific relevance

Conclusion: “The whole is greater………”

There can be little doubt about the significant contribution made by Mahle.The Renault Turbo engine was a tour de force and the German manufacturer made it possible.Although Lotus were not able to achieve F1 ultimate success they were on an important upward learning curve.

Components were material to reliability and competitiveness.

Mahle is an extremely important and innovator of international standing.

The editors offer a perspective:

In 2020 Mahle has celebrated its One Hundredth Anniversary, its success due to innovation, quality, research, motor racing success (in F1, recently with Ferrari, at Le Mans and in power boats ) , they are exploring sustainability in various forms relating to the car and other fields
The company has a well advanced and established staff welfare scheme that has a basis in the modern Germany that was propagated by the Bauhaus in the 1920’s this deserve serious study (see our dedicated articles on design Heroes and the? Bauhaus )
We have learnt from published authors that the Renault engine required international cooperation to create and that Mahle were successful in this

We invite subscribers to view Mahle’’s website. We quote from them regarding their objectives:

“MAHLE is a leading international development partner and supplier to the automotive industry as well as a pioneer and technology driver for the mobility of the future.

The MAHLE Group is committed to making transportation more efficient, more environmentally friendly, and more comfortable. MAHLE is continuously optimizing the combustion engine, driving forward the use of alternative fuels, and laying the foundation for the widespread acceptance and worldwide introduction of e-mobility.

Based on a broad systems competence consisting of Engine Systems and Components, Filtration, and Thermal Management, the group’s product portfolio addresses all the crucial issues relating to the powertrain and air conditioning technology. Thanks to its expertise in electric and electronic components and systems, MAHLE can thus also offer integrated system solutions for e-mobility.

MAHLE products are fitted in at least every second vehicle worldwide. For decades, MAHLE components and systems have also been used on the world’s racetracks and off the road—in stationary applications, for mobile machinery, rail transport, as well as marine applications.”

Chapman’s design and manufacturing methodology rather confirms the adage that “the whole can be greater than the sum of the parts”.

It’s an interesting an important study to consider deployment of components. It contributes to aesthetics, assembly economics and sales [attractive components/ known accepted performance and servicing ability etc.]

It is equally and mutually relevant and beneficial to the component manufacturer.

Chapman and his colleagues often took the best / most appropriate mass produced item and almost reinvented it in its service to design objectives. In this manner many components acquired a new status and indeed their aesthetic was enhanced surrounded by the Chapman conceptual whole.

It’s also extremely significant how many of these components were also used in Lotus competition cars. This created a powerful dynamic and interrelationship. Many components:-

Performed well in competition gaining beneficial publicity and sales
Both the component and racing reputation carried through to road cars and assisted sales
The component manufacturer gained disproportionate publicity and assisted products sell in other applications
All together a beneficial spiral was commenced. Publicity of the era often opted to highlight the Lotus dimension in publicity material. In fact there was a powerful synergy.

The relationship between Lotus and is sponsor specialist suppliers is significant and worthy of close study and has lessons for Engineering, Industrial Design and Manufacturing disciplines.

Along the way it’s possible too to study the wider British motor component industry and how it has helped foster the specialist car manufacturers.

Sponsorship is a worldwide phenomenon of immense commercial impotence. Both to host and sponsor organization.

With the Passage of time it’s likely to become more sophisticated and focused and the internet /multimedia technology will play greater role.

Sponsors have existed in motorsport before Chapman but he vigorously exploited the concept with Gold Leaf c 1967/68 and set a pattern for others to follow.

Sponsors of Lotus were likely to benefit financially and in terms of exposure to an extent greater than their investment. The benefits were, and remain essentially similar to present day:-

Access to mass international audience consistent with mass production distribution marketing branding etc.
Demographics of viewing audience and interest groups
Additional subsidiary /secondary advertising through media, news, magazines etc.
Identification with market /brand /marque leader in both F1 and road cars
Association with success and continuity evolving, developing technology, materials etc.
In period the identification with the charm ,charisma and ability to articulate that Chapman possessed
All the attendant glamour , drama ,danger ,and spectacle of F1
Ability to provide conducive hospitality to conduct business
Cost effectiveness of audience cost ratio
Possible further complex corporate benefits

Appendix 1: Context and operation of sponsorship from the net:-

Learn how sponsorship motives have evolved.
Be able to differentiate between advertising and sponsorship.
Learn the advantages of each of the key promotion tools.
Identify the six categories of sponsorship opportunities.
Distinguish between self-evident and strategic linkages.
Learn the trends in spending on sponsorships.
Gain insight as to how ambush marketing and leveraging play roles.
Develop a basic understanding of the three special cases of sponsorship.
Identify the five key sponsorship objectives.
Learn the importance of each sponsorship objective.
Understand the concept of matching.
Learn the potential components of a sponsorship plan.
View a comprehensive example of a sponsorship.

Gain an awareness of controversies regarding sponsorship.

Appendix 2 F1 and related racing results

http://www.snowmoose.com/LotusCars/TeamLotus/TLHistory.html

Reference:

Marks of Excellence.P.Mollerup.Phaidon Press.1997.

ISBN: 0714838381

Graces Guides

Internet websites and local History

Aircraft of the Fighting Powers.Cooper&Thetford.Vol.1.Aircraft [Technical] Publications.1940.

An extensive bibliography is provided in A&R article on John Players Specials/Gold Leaf

Industrial Design A-Z.C&P Fiell.Taschen.

ISBN: 3822863106

Lotus Book.Taylor.Coterie.1998.

ISBN: 1902351002

Art of the Formula 1 Race Car. Mann, Codling.Motorbooks.2010

ISBN:

Lotus 24, 25, 28, 29, 33.Unique.

Lotus 49, 49B, 49C, 49F.Unique.

ISBN: 1842555185

International Corporate Identity.Olins.Laurence King.1995

ISBN: 1856690377

International Motor Racing 1978.Ed by B.Gill.Macdonald and Jane’s.1978

ISBN: 035409033X

The International Motor Show. Offical Catalogue.1966

Motor Racing Directory 1955-56 [Ed by staff of “Motor Racing”] Pearl Cooper.

Motor Racing Directory.Kettlewell.

ISBN: 0906556007

Autosport A-Z Motorsport Directory. [Annual editions] Haymarket

The Automobile.Reyat.Chand.2013.

ISBN: 8121902142

Fundamentals of Motor Vehicle Technology.Hillier & Pittuck.Hutchinson.1967.

Lotus 49.Wagstaff.Haynes.2014.

ISBN: 9780858334121

Lotus 72.Wagstaff.Haynes.2012.

ISBN.978857331274

Colin Chapman.Lawrence Breedon.2002.

ISBN.1859832784

Colin Chapman.Ludvigsen.Haynes.2010.

ISBN.9781844254132

Coventry Climax Racing Engine’s.Hammill.Veloce.2004.

ISBN.1903706831

Lotus, Coventry Climax and Cosworth Engine’s.Pitt.Unique.

The Anatomy and Development of the F1 Racing Car.Incandela.Haynes.1982.

ISBN.

The 1000 BHP GP cars.Bamsey.Haynes.1988.

ISBN.0854296174

Lotus 98T.Slater.Haynes.2016.

ISBN.97808573377771