Lightyear MX5 NA/NB Fastback

[pac-man 99]

I'm so ready to purchase this! Hope we can arrange some shipping to the U.S.!

[lightyear]

I hope I can organise a group buy at some stage and pack a container, or large box.

The gel coat is on the main section of the mould for the roof. It will be a multi part mould as the window frames are recessed. Getting there


photoupload

[Chicken_Lips]

Very excited to see the end result. Maybe one day I'll grab one.

One question. What are the issues regarding ADR's and the hardtop? Are there any rules that need adhering to or not? I actually wouldn't really care if I was to buy one, just a thought I had.

The following is from the NSW RMS light vehicle modifications guide.

22
Fitting of fibreglass body panels where the original panels were welded on or where structural integrity is affected.
Examples requiring certification:
• Fitting fibreglass body panels where the original panels were welded on.
• Fitting fibreglass body panels causing any change to the structure or the body of the vehicle.
Example not requiring certification:
• Replacing original bolt-on mudguards, bonnet, or boot lid with identical fibreglass panels.

23
Change of body style (eg convertible conversions; panel vans to utilities; sedans to coupes and ‘tudors’; ‘chop top’ conversions; and tilt front conversions) or changes to body that affect structure.
Example requiring certification:
• Conversion from a sedan or a coupe to a convertible.
Example not requiring certification:
• Fitting a fibreglass canopy on the back of a ute where the original structure is unaltered.

The following is from ADR 42/00 (there are other 42/** and I would be lying if I said I knew what the second part is but they all seem to say the same thing).

42.9. EXTERNAL OR INTERNAL PROTRUSIONS
42.9.1. No vehicle must be equipped with:
42.9.1.1. any object or fitting, not technically essential to such vehicle, which protrudes from any part of the vehicle so that it is likely to increase the risk of bodily injury to any person;
42.9.1.2. any object or fitting technically essential to such vehicle unless its design, construction and conditions and the manner in which it is affixed to the vehicle are such as to reduce to a minimum the risk of bodily injury to any person;
42.9.1.3. any object or fitting which, because it is pointed or has a sharp edge, is likely to increase the risk of bodily injury to any person; or

42.10. FIELD OF VIEW
42.10.1. A motor vehicle must not be so constructed or equipped nor must anything be affixed thereto in such a manner as to prevent the driver from having an adequate view of traffic on either side of the vehicle and in all directions in front of the vehicle to enable the vehicle to be dríven with safety.

This document says "The thickness, of non-intrusion panels, with gel coat removed, must be at least 3.5mm.
Bonnets and guards are examples of non-intrusion panels." And it talks about having fibreglass structurally tested.

Finally, I found this bulletin from WA, which says that you can't modify the vehicle without an engineer's OK. Again, hardtops seem a grey area, I can't seem to find specific legislation.

I think the safest route would be to involve an engineer in the initial development and have the hardtop signed off, unless the engineers say that a fastback is not structural. I'm happy to do this research if Lightyear is happy to consider ADR compliance for road use.

P.S. I'm super keen for a fastback - have been a forum lurker for over a year and had to sign up to register my interest.

[lightyear]

These will be sold as off road use only items. From reading that, there is nothing relevant to the fastback. The thing is, your swapping from a fibreglass bolt on non structural roof, to a fibreglass bolt on non structural roof in a slightly different shape.
A fibreglass canopy on a ute needs no engineers. I am happy for you to look into it further. As I can't see it would need engineers. Bit it doesn't hurt to confirm it.

[Corey]

Best thing would to sell for off-road use anyway, as lightyear said. Theres nothing wrong with running these fastback hardtops on the street and it doesnt fall under any of the ADR rules saying it needs to be engineered or illegal.

[Mr nanotech]

So what kinda price range are we looking at and what kinda price in terms of group buy?

[lightyear]

I have to make one before I know how much they will cost. But I am trying to keep the price around $2000. It is a complete roof, and complete boot. So I have to make two inner and outer parts, windows, brackets, rubbers, hinges, etc, etc.

[Chicken_Lips]

I have had a response from peter at adr compliance services in sydney. He says that the glass will need to meet a certain standard for road use and it will need to be certified. I'll keep you updated.

[lightyear]

I use polycarbonate. It won't shatter like glass or Perspex.

[lightyear]

the main section of the mould is done. Now to do the frames. And make a box that it will sit on when turned over.

upload an image

[lightyear]

The frame/box is on. The sides are now all prepped and in gel coat. So today the whole mould will be complete.


screen shot pc

[mx5002]

Looking good.. Maybe the roof box could be an optional extra for carrying spares to the track

[lightyear]

The side window frames are all done. So now I just need to trim the edges, wrestle it apart, clean and prep it, and it's ready to go. The boot section has been trimmed, the boot pulled out, and moulds have been cleaned. So by lunch time tomorrow it should be ready to go. I think the first Lightyear Fastback should be vacuum infused carbon fibre. Only seems right, since it will be going on my car. They will be sold as fibreglass standard to keep the price down.
I will be painting my fastback silver to match the car. So only I will know it's carbon fibre. And whoever reads this....

[plohl]

How much do you think weight difference will be between the carbon and glass dude? For the same stiffness?

[lightyear]

Well, the hardtop I just made in fibreglass weighs 2.5kg's more than the c.f one. So maybe 3.5-4.0 kg's heavier all up. Will find out soon. But won't be as stiff. Once it's on the car, the stiffness is not much of a concern.