Yotoda - Quality Policy
General assumptions of the project
There were several conceptual assumptions during the creation of the Yotoda prototype. One of them was to build a car based on the existing model of an off-road vehicle which had been positively verified by at least several years of use. It was no accident that Toyota had been chosen for this project. Undoubtedly, this make of car is associated with manufacturing the most durable and reliable off-road vehicles worldwide, having rich experience and raising the bar to the highest level from among the manufacturers of four-wheel drive off-road vehicles around the world. The decision to base our design on a particular car model allows us to purchase 99% of spare parts on the basis of the VIN. Owing to that, Yotoda vehicles can be used in all corners of the world and every motorcar mechanic will easily handle their servicing.
The next assumptions which we followed while constructing both the Yotoda prototype and the production model were to minimise the weight of the car ready for start and keep its centre of gravity as low as possible.
In fact, it is not the power of a car, but its power-to weight ratio that counts. It is always worth it to strive for low weight. Let us assume that we have two cars with identical power-to-weight ratio: then the lighter one will be faster anyway. Why? During acceleration, both vehicles will behave similarly, however during cornering the lighter vehicle will prove considerably faster. The weight of a Yotoda car ready for start in a rally, depending on the model, oscillates between 3,306 and 3,747 lb, including the full fuel tank.
Another assumption made by our team while constructing the Yotoda car was the safety of the vehicle users. That is why we constructed a roll cage based on the FIA technical regulations which specify the cage design itself.
Owing to the adopted strategy, our team managed to implement very important assumptions which characterise Yotoda:
- - reliable design
- - easy vehicle servicing
- - user safety
- - low vehicle weight and very good power-to-weight
ratio of the car.
Performance
The engines used in our vehicles, operating at around 198 hp, combined with the vehicle weight oscillating between 3,306 and 3,747 lb, and the centre of gravity located as low as possible, all ensure considerable advantage over heavier rally vehicles popular around the world. The acceleration from 0 to 62 mph for the model equipped with the 3.0 D4D Diesel engine amounts to 7.2 s.
| Diesel 3,0 D4D | Gasoline 3,4 V6 | Gasoline 4,0 LS 400 | |
|---|---|---|---|
| engine power | 197 HP/ 2800 rpm | 204 HP/ 4200 rpm | 283 HP/ 5100 rpm |
| torque, max | 475 Nm/ 2600 rpm | 350 Nm/ 3200 rpm | 410 Nm/ 4000 rpm |
| gear box | manual / automatic | manual / automatic | manual / automatic |
| fuel tank capacity | 109 l | 109 l | 109 l |
| acceleration 0-62 mph | 7,2 s | 7,0 s | 6,4 s |
Suspension
Every user of a sports car knows that the suspension of a car is the element of crucial importance. Yotoda cars have been equipped with 8 shock absorbers with external tanks filled with nitrogen, the performance curves of which can be set individually, in order to meet the requirements of the client. By default, Yotoda cars are equipped with King or Fox shock absorbers. In the case of the basic versions of the vehicle, these are Koni shock absorbers.
Lightweight design
Owing to the implementation of state-of-the-art technologies, we managed to create an ultra-light vehicle which ensures remarkable off-road driving experience. Yotoda cars are intended for off-roaders with shaped personalities, who crave to experience only proven technical solutions that ensure long-lasting use and reliability in off-road conditions. The very concept of combining a minimalistic frame cage with the elements of an epoxy body ensures an exceptionally lightweight design. At the same time, focusing on making the details of vehicle equipment as light as possible makes a Yotoda car appear as if it denied the laws of physics while driving in off-road conditions. The independent suspension of the front axle, with a travel of 22 cm, and the rear suspension system based on a rigid axle and spring suspension guarantee the driver a high degree of control over the vehicle at high speeds.
The floor of the cabin and the engine bulkhead have both been made of aluminium panels of 2 and 3 mm in thickness, whereas all non-bearing surfaces have been made of polycarbonate resin or acrylonitrile butadiene styrene (ABS). Making the low weight of the vehicle its basic asset, we decided to provide the vehicle with only one spare wheel and the minimum required internal equipment.
Corrosion protection
During the construction of a Yotoda car, we reach a stage in which corrosion protection needs to be applied. The frame cage made during the construction stage is first subject to mechanical pretreatment and then covered with barrier epoxy coatings characterised by high abrasion class rating and high degree of weather and chemical resistance. Next, the external surface of the structure is finished with polyurethane coatings characterised by the highest degree of scratch and abrasion resistance.
Safety
User safety is the priority in Yotoda policy. In view of that, every vehicle bearing the Yotoda mark has been equipped with a roll cage made of seamless pipes, based on structural designs recommended by the FIA. Every vehicle is equipped with bucket seats, sports seat belts and a fire-extinguishing system or hand-held car extinguishers.
Field tests
The prototype was developed on the basis of a rally car which had participated in cross-country rallies in 2010 and 2011, and was well-known for our team. As far as technical issues are concerned, the car was as similar to the T2 class as possible and we constructed it in accordance with the so-called J appendix of the FIA regulations. These two years of using the Toyota Land Cruiser J9 gave us the possibility of detecting weak links and reinforcing all structural elements for which such a treatment was required - e.g. front suspension arms, the frame or shock absorber mounts. At that stage, the vehicle weighed 4,850 lb and all component modifications have been tailored to that weight. This means that the structural reinforcements of a Yodota car - which is 1,322 lb lighter than its ancestor - are exaggerated, to a certain extent. Perhaps it comes into conflict with the concept of low vehicle weight, but at the same time it means less breakdowns while using the vehicle in rally conditions.
| overall length: | 362 cm |
|---|---|
| overall width: | 189 cm |
| overall height: | 172 cm |
| gross weight: | 1470 - 1640 kgs |
| wheelbase: | 270 cm |
| approach angle: | 82° |
| departure angle: | 90° |
| minimum ground clearance: | 30 cm |
| wading depth: | 120 cm |
| suspension travel: | 22 cm |
Eco policy
Meeting the expectations of off-road vehicle users who care about ecology, Yotoda cars have been manufactured on the basis of recycling the vehicles which already exist on the market. We have created a rally car based on the proven and popular model - Toyota Land Cruiser J9 - taking advantage of technical solutions used in its reinforced frame and suspension.
The ultra-light and innovative body has been developed with non-toxic epoxy composites, as well as lightweight Diolen® and glass fibre. As a result, we have created a vehicle which offers its users remarkable aesthetic experience and a whole new quality of fast moving in off-road conditions. Moreover, the use of products of animal origin has been virtually eliminated in Yotoda cars.
Design
Yotoda tailors the colouring and equipment of its vehicles to the individual needs of the client. The design may feature both technical parameters, such as the selection of elements and suspension performance curve, and the external appearance of the car. Owing to a creative team and artists involved in the project, a Yotoda car can emanate the atmosphere and colouring of your choice.
How is a Yotoda built?
The following question comes to the minds of everyone interested in the Yotoda car: Since the car is made of used parts, then what is its quality?
First of all, in order to begin the construction of a Yotoda, it is necessary to have a Toyota Land Cruiser J95. We survey the used car market and select a well-maintained car in good working order, made between 2000 and 2002. We never use crashed and salvage vehicles. First tests involve the engine of the vehicle. The best way to test it is when it is installed in the vehicle. We check the engine’s compression ratio and the operation of individual fuel injectors. Then, if necessary, we eliminate any possible leakages, using original parts exclusively. The engine is the only element of a Yotoda that we do not take to pieces. We think a factory-assembled drive unit will prove to be the most durable one. Other elements of the power transmission system are dismantled and reassembled with the use of components in good working order exclusively, after prior verification of individual elements. The same goes for brakes and suspension.
A Yotoda is delivered with brand-new king-pins, polyurethane bushings for the whole suspension system by SuperPro, brand-new steering rod ends, DBA brake discs, wheel hub bearings, clutches and water pumps, as well as with a range of shock absorbers to choose from: Fox, King and Koni. In addition, the owner of a Yotoda receives a list of spare parts which have been used in the car, apart from spare parts by Toyota. We also conduct training in the construction of the car for motorcar mechanics who will be servicing the car in the future, during off-road races.
The construction of a Yotoda begins with the preparation of the chassis frame. It is appropriately shortened and reinforced in all points for which such a treatment is required. Lower front suspension arms and king-pin holder mounts are also reinforced. Then the frame is equipped with a roll cage made of seamless pipes with design recommended by the FIA regulations. The installed cage is an element that does not receive homologation. At the same time we utilise full safety assumptions to construct it. Afterwards the assembly elements for all components are fastened to both the cage and the frame of the vehicle. The engine is moved towards the rear of the vehicle by 48 cm. Therefore, it receives new cushion mounts. After finishing fitter works, the time comes for sand-blast cleaning and painting the frame cage of a Yotoda. Painting is done with the use of epoxy paint and then polyurethane lacquer of colours selected by the client.
The assembly of a Yotoda begins with putting it on wheels. Then the engine, the gearbox, drive shafts and other components are installed in the vehicle one by one. The floor and the engine bulkhead are made of 2-3 mm aluminium, whereas the rear wall of the cabin is made of acrylonitrile butadiene styrene (ABS) and colourless polyurethane.
The braking system does not feature the anti-lock braking system (ABS) and is equipped with a manual braking-force regulator for the rear axle. Due to specific regulations which apply to some 4x4 rallies, a Yotoda is equipped with a mechanical parking brake for the rear axle.
Before equipping the cabin the wiring system of the vehicle is laid. Here we fully utilise the wiring system that comes from Toyota Land Cruiser, which is assigned to the on-board computer and the injection system of the car. Due to using as much of the factory system by Toyota as possible, we gain the reliability of all contacts and connectors. We strive to minimise our interference in the factory system. Owing to that, it is possible to connect a Yotoda to a diagnostic computer at every Toyota showroom worldwide. The exhaust system of a Yotoda, 70 mm in diameter, is insulated with fire-retardant tape and is not equipped with mufflers. Also the floor of the cabin at the bottom of the vehicle is lined with thermal insulation.
One of our assumptions made during the construction of a Yotoda prototype was to use the conditions which the car is subject to while driving. A Yotoda has a double-layer roof, owing to which large volumes of air reach the rear part of the body. This is the place where a radiator is located. It prevents excessive outflow of accumulated air. The positive gauge pressure that forms inside the rear chamber is used to supply air to the air filter, the location of which – next to the pilot’s seat inside the cabin – is quite untypical. Moreover, we have utilised a second air tunnel which runs along the left edge of the car and supplies air to the heater blower.
The body of a Yotoda is made of epoxy composites and its characteristic features are low weight and high impact resistance. A Yotoda has a futuristic look and in some countries it cannot be registered with a valid MOT certificate. The car is delivered to the client as a Toyota Land Cruiser, together with the documents of the car, on the basis of which it has been built.