OVERVIEW
The 3.5 RL has a stamped-sheet-steel unit-body structure that
contributes greatly to an overall feeling of solidity and poise.
Created with the same NASTRAN stress-analysis software used
to design
the space shuttle, this lightweight yet extremely rigid structure
offers a high level of overall rigidity in both bending and torsion.
The chassis is made even more rigid by a rear support gusset, a
large
bulkhead bracket and a rear crossbeam stabilizer.
The high rigidity of the 3.5 RL unit-body structure offers superb resistance to vibration while providing a firm platform on which to maximize the performance of the suspension system. Insulation has been added at critical points to reduce vibration and noise. Lightweight honeycomb panels in the floor provide additional structural stiffness and help absorb road noise. A high proportion of galvanized panels are used in the 3.5 RL structure and body panels for enhanced corrosion protection and overall longevity.
OVAL-SECTION FRONT TOWER BAR
Instead of a conventional tubular steel front brace between the
firewall and the upper front-suspension locating points, the RL
uses
an oversized, oval-section tower bar brace, as well as a
reinforced
plate that ties the firewall to the front cowl section. This design
increases rigidity as much as 12 times compared to a
conventional
round tube design, reducing cowl shake on rough roads and in
spirited
driving, while increasing steering precision.
FOAM-FILLED A-, B- AND C-PILLARS
For reduced cabin-noise transmission, the A, B- and C-pillars
are
filled with a special heat-expanding, rubberized foam material
that
expands to fill the hollow pillar during the baking cycles of the
painting process.
HONEYCOMB FLOOR PANELS
Special lightweight honeycomb panels are used in the floor
structure
to increase rigidity and reduce noise and vibration. These panels
are
composed of a resin-impregnated fiber matrix bonded on top
and on
bottom to thin-gauge galvanized steel sheets.