While many rightly worship Lexus' howling naturally aspirated V10, the story behind the LFA’s production and engineering is just as mind-blowing.
BY SAM MAIN
VIA HOTCARS
PUBLISHED MAR 2, 2023
The Japanese brand Toyota has many achievements under its belt. It’s an icon of the JDM scene, it was innovative during Formula 1, and it oversaw Lexus’ production of one of the all-time iconic supercars: the Lexus LFA.
What separates the LFA from its rivals is not just its intoxicating engine. It’s the story behind its development. A nearly $1 billion project that was, in effect, an experiment for Toyota to show the world what it was capable of.
So, Toyota's 'luxury' division, Lexus, embarked on a truly fascinating research and development project that faced Herculean obstacles. And whilst many worship the incredible engine note from its V10, the actual production story of the LFA is a perfectionist story worth telling.
Toyota’s Dream To Make The Ultimate Supercar
When Haruhiko Tanahashi was quizzed by his superior on what Toyota should embark on, he simply replied: “I want to make the ultimate sports car”. At the time, Toyota was a competitor in the glory days of Formula 1, the V10 and V8 era. During this period, F1 was less about over-strategizing and more about achieving engineering perfection through innovation. But after many racing errors, Toyota was at the back of the grid. Their F1 project was a failure. Something needed to be done.
That’s when Tanahashi was handed the ropes for the LFA project. They were given a mission: to show the world what they could really do with a sports car. Early on, they knew the car had to give a raw, purist experience and be a true high-end sports car. They also knew the car would have a V10 engine derived from its motorsport career in F1. But at its core, the car had to communicate with the driver and be a true driving machine. This was a fundamental ethos that never wavered.
Stop-Start Engineering On The Lexus LFA
The only time ‘stop-start’ can be associated with the LFA is not because of some eco-friendly fuel-saving system. It’s because of the production journey. Like the honeymoon phase of a relationship, the start of its development went smoothly. The car was to have a full aluminum chassis, with all its components made in-house by 175 of Toyota's best employees, all specifically chosen for the project.
However, after five years into development, the engineers had a thought: why not construct the car out of carbon fiber instead of aluminum? This presented an issue. Lexus’ team didn’t have the knowledge or resources to do so, but they knew switching composites would make for a better automobile. Sticking to their ethos, it was decided. Carbon fiber was the way forward.
The team approached Subaru and inquired into carbon fiber construction, with the famed rally experts telling Lexus they would need at least 10 years to R&D its fabrication. This didn't cut it. Lexus needed the car done in a single year. And after the best minds in the business pushed the boundaries on what was technically possible, the car ended up being put into production on time in late 2010. The LFA was made of 65% carbon fiber and 35% aluminum. Production, quite literally, stopped and started to change the entire structure of the car.
Lexus LFA Was Ultimate In Engineering And Driving Dynamics
The result of this enormous production process was, quite simply, the ultimate supercar from a manufacturer that strived to provide the perfect driving experience. Every component on the LFA was bespoke, with its design prioritizing space efficiency. It had an aluminum sub-frame and steering rack. The latter was electronic, not hydraulic, to prevent unnecessary lines and pumps from taking up space. The KYD dampers were derived from Toyotas’ racing career, costing $9,500 per shock. Then came the $3,800 carbon-ceramic brakes, which were a first for Lexus and had hollowed-out pistons to reduce the temperature in the brake fluid.
To prioritize driving dynamics, a 6-speed automated single-plate dry clutch was used, coupled with a limited-slip differential. While not as quick as a dual-clutch, the single-clutch let the driver hear and feel each gear being slotted into place. The exhaust system was made from titanium. And 2 enormous air ducts on the rear fenders channeled air directly into heat exchangers, while 2 radiators mounted by the rear bumper cooled down the monstrous V10 under the hood.
Lexus LFA's V10 Was Derived From Formula 1
Much has been said about the LFA’s legendary 4.8-liter naturally aspirated V10. A motor that was hand-built. A piece of automotive triumph that went from 0 to 9000 rpm in 0.6 seconds and produced 563 hp and 354 ft-lb of torque. An aluminum engine that was the size of a V8 but weighed the same as a V6. But as amazing as these statistics were, the production story – yet again – is one to behold.
Lexus sent the engine to Yamaha (the maker of some of the best motorbikes and musical equipment on the planet) for one thing to be mastered: the V10’s sound. Lexus wanted to replicate the experience of the V10 era of F1 in the LFA. And so, Yamaha produced a ribbed intake manifold that channeled both induction and exhaust noise into the cabin. The occupants were then treated to the most glorious, harmonic, soul-touching symphony produced by any engine ever made: its 4.8-liter V10.
This story has captured just a figment of what technical innovations Lexus made when making the LFA. But the LFA was met with confusion; a high price tag and mid-supercar performance put people off. But the LFA was never about numbers. It was about maximizing the driving experience, a sensation it delivered in spades thanks to its handling, its power, and its V10 symphony. And arguably, no car has achieved such a sensation since. The LFA may very well be the last hurrah of the conventional supercar.
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