this normal golf 5 should become a fuel-saving car over the next nine weeks we will try to reduce consumption to three liters a difficult task for our reporter lars haust he should convince well-known automotive suppliers to help us he has already convinced one of the porsche tuner 9ff god from dortmund our trainer golf, company founder trusted for years, plans the conversion for us and the team from 9ff screwed together our dream of the 3 liter golf flashback we bought a golf the dekra measures a consumption of 5.6 liters can dismantle what is too heavy and must out our concept stipulates that more than 40 components are exchanged for lighter ones the goal of the golf should be less than 1000 kilograms of comfort and the same level of safety at the moment there are 1360 kilograms on the bench we have the battery the bayer is super heavy but there is something light otherwise what do you think me I hope maybe from racing because the new technology gives lithium ions and im cellphone cellphone but if there was it would be actually a is a car already there or was perhaps the prototype was embarks snugly auto pay to our on the search ok I watch myself reverses meanwhile, our reporter at a chemical giant in marl here one is working feverishly to ensure that the high-performance lithium ion batteries can also be installed in cars and, above all, are allowed to be installed because so far the batteries have not passed this so-called nail test, it simulates the penetration of metal into the battery, as these recordings show in a car accident a short circuit occurs and the battery explodes because lithium-ion batteries are more powerful and significantly lighter than conventional batteries, they are ideally suited as a source of energy for the future-oriented hybrid vehicles, which is why the researchers do not give up and develop special components with which the new types of batteries no longer pose a safety risk and the current comes from these inconspicuous cells the current flows with lithium ions through a membrane from plus to – pool migrate the membrane is permeable for the particles trend but plus from – because otherwise it would lead to a short circuit breaking in the metal part as in the nail test Although the membrane with its special properties ensures that the inevitable short circuit has no consequences during the test, a little bit of smoke rises to nothing more than this battery is sure we want to see that quickly you can also turn it off then it has to be convincing again i say i'm heavy this thing is now 2.5 kilos 25 kg the new battery austria he said super light would be measured enormously home building the lithium ion battery was given an additional plastic jacket overall we now save 16 kilograms because of the only advantage that kills us to see how strong this battery is no longer highly scientific test let's put up with the fact that on this fan we now have the two conventional batteries and our new one and I have power supply for the fan it was now we want the wishes of the measured around 30 not bad back then then it’s okay okay and now the new battery so I’m holding on to everyone as a co- worker over the age of 40 my dear husband and I would say go on to degussa in darmstadt here the experts are researching new ones to set the lubricity to improve engines and gears specially for our engine the experts develop a special low-friction oil the addition of chemical substances ensures that the oil minimizes the friction in the engine at any temperature today the oil mixture should be checked after weeks of tests so our man must not be missing Hello everyone, I would have greeted you from him, yes, I have the beautiful battery and we had phoned the i Now is our new engine oil that gives the remote IO module super-g, we will probably save with it, let's start now, test it, then let's see the consumption measurement begins, the engine completes exactly the test run that our golf already underwent during the initial measurement had to serve as a comparison, the consumption values which had the motor previously achieved with normal oil the advantage of a test rig, the engineers can permanently here pressures and temperatures in the individual motor share monitor and observe after 20 minutes, the test ends the pre-selection of different relative studied between 2 and We took 4 0 in oil with 4 0 and the result is 4 40 percent on 1 fuel savings that is compared to an industry references that is a lot that we expected but we also know which components have to take that you now have extra for our three liters of gold formulated and the gear oil also helps tstoff to save in this test system shows that our golf sport triebel reduces consumption by another percentage scary fuel with why there is as yet to buy or why not on the non-factory already in the call cars so you can not say there are solutions the reason is an economical and economical the components we have taken for this golf they are extremely expensive both in terms of the basic tones and the additives and the market also demanded a cheap oil yes what does it mean extremely expensive extremely expensive means with a filling of a vehicle in the euro area maybe 23 so i have to say the money we invest our reporters according to faust, meanwhile, on his hunt for lightweight components, it has ended up in hengersberg in bavaria the tinny bonnet and the tailgate worry the parts are simply too heavy here ours should reporters are actually correct in this company represent more than 2 00 employees produce lightweight components every day, especially for the aviation industry but also for high-tech racing with almost 30 years of tradition and there is already the shape a model maker made it with a kind of plaster cast of the original now the carbon is not even a millimeter thin the front then followed a layer with this white foam and then again carbon fiber the mats are soaked with resin that begins to harden as soon as the film is removed the whole thing is now in an oversized bag and vacuum sealed so that nothing can slip it goes for five hours with heat and pressure in the autoclave we have the carbon fiber from the tool then this foam core comes as a sandwich and the rear structure is additionally provided with carbon again and then the following happens in the autoclave that the pressure these components how important torments together and the vacuum and the temperature the 1000 pr The white foam is the secret of the stiffness of the parts and the rigid foam was developed in 1970 for your darmstadt.The starting material is these amber-colored panels they consist of an inexpressible chemical compound, the clou and the heat, the panels expand and wedding street art is rigid and light the inside of the wings in airliners consists of this foam, for example, that looks i would say like a large mattress is also a foam is called hc and she tells us the expert is good for it do it or do it right away a little carbon fiber on it not a lot of percent is very firm and stiff you only need small amounts of this carbon fiber this is expensive it saves costs and but also great weight because i would say thank you very much even if you did not invent it yourself then Let's see if it's really fun ctioned back in the Bavarian town of Hengersberg our bonnet and tailgate are completely baked the result is overwhelming that looks sensational that is carbon look i think that we would rather not paint it is also easy to do a small test but with the tailgate just as that is unbelievable girl the original tailgate weighed 22 kilos I still know exactly how heavy the part is it is almost five kilos sensational weight savings now tell me these parts are now very expensive that is quasi custom-made for our three liter golf you could also get yourself imagine that something like this will be built into series production in the near future , so if the components were already designed in the direction of plastic technology with previous developments , there are already interesting processes that we practice and which then also allow the parts in series to represent an acceptable price I sometimes need to help with the part it is not really light enough for me and i would say we’ll see you from the new carbon parts our designer is enthusiastic times flap visual gain with simultaneous weight loss so it can go on because of the exhaust system the hood has now got additional air outlets sporty sporty overall we save with the new one bonnet compared to the original nine kilograms and the parts fit like a glove, the tailgate what is still missing is a window that is lighter than the original so our reporter makes his way back to darmstadt in these halls in 1933 a chemist named otto röhm has the acrylic pane was invented and it is called sexy glass here the experts manufacture the rear window for our golf the original glass serves as a specification but how break-proof is such a plastic we do the test, of course, we only take the plexiglass pane if it is stable enough and you test something like that with a ball f alltest that is a steel ball, I drop it from four meters height on this piece of plexiglass then let's see if it holds vans are you okay so far 321 hopp i would say holds is a small jump in it but that is okay test passed and after an hour our new windshield has called the desired culture that is I think our new rear windshield is really great this nice and easy it can definitely be seen through well you can also mention you are responsible for these plexiglass panes why are they not actually from series built-in that is mainly due to the price you a glass pane is cheaper than a plastic pane and in the past it was still so that the scratch resistance was worse than glass but with the new scratch-resistant sheets the problem would be solved and we can start super in any case thank you and so our tailgate is even more than a kilogram lighter parts take into account how he saves a whopping 13 kilos in the netherlands eight weeks ago our reporter ordered fuel-saving tires for our three liter golf 165 he tires for a 16 inch rim such a dimension is not available in stores, this is our new one tires for you and that was the predecessor ok it is black and for me it looks like normal tires what is special about it on the one hand because you can clearly see the tread width it has become very narrow that was the previous model is much wider and there is very, very light so I still know the old tire that was originally on it, why the eight kilos as always on such occasions, I only have a vague with me and now I'm curious what this is with 5.8 of the original vogue 78 kilograms together So let's save a total of eight kilograms.
Very important for the consumer is the rubber compound used, which is more than 20 different substances and forms n the rubber tire, together with the chemical giant degussa, the dutch tire manufacturer has developed a rubber compound that has particularly little rolling resistance, however, every rubber compound is a compromise, for example a higher proportion of silica improves rolling resistance, but our tire could still play a real pioneering role take to find out whether the custom-made product actually helps to save fuel we do a test this machine presses the tire with the subsequent vehicle weight on the ground this is how the experts measure the rolling resistance in december many numbers the test is over a new tire is now really better this one with the blue line the previous tire red line optimizes the rolling resistance so that it has up to 60 percent, i.e.
60 percent less rolling resistance, the new tire is the way it is so that you can save fuel, I would say that you can still drive a car with these tires sensibly ren but the problem of the endurance test with an audi a6 the car is almost twice as heavy as our golf we and the development engineers want to know how the tires hold and what is the grip and that takes a while but of course the tire is a prototype it should even go into series production soon our project seems to make a difference, so the second launch for our fuel-saving car today, the driving resistances are to be determined in the so-called roll- out test, here on the test track in papenburg, but initially the scales initially weighed the golf 1360 kilograms now it is a fabulous 999.