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Tougher than steel: Wood pulp could make lighter auto parts

KYOTO, Japan — The global push among carmakers to make ever lighter vehicles is leading some auto suppliers in Japan to turn to what seems like an unlikely steel substitute — wood pulp. Japanese researchers and auto component makers say a material made from wood pulp weighs just one-fifth of steel and can be five times stronger. The material - cellulose nanofibers — could become a viable alternative to steel in the decades ahead, they say, although it faces competition from carbon-based materials, and remains a long way from being commercially viable.> Related: Jay Leno drives the Renew cannabis car — hemp you can't dent Reducing the weight of a vehicle will be critical as manufacturers move to bring electric cars into the mainstream. Batteries are an expensive but vital component, so a reduction in car weight will mean fewer batteries will be needed to power the vehicle, saving on costs. "Lightweighting is a constant issue for us," said Masanori Matsushiro, a project manager overseeing body design at Toyota. "But we also have to resolve the issue of high manufacturing costs before we see an increased use of new, lighter-weight materials in mass-volume cars."A NEW PROCESS Researchers at Kyoto University and major parts suppliers such as Denso Corp, Toyota's biggest supplier, and DaikyoNishikawa Corp, are working with plastics incorporated with cellulose nanofibers — made by breaking down wood pulp fibers into several hundredths of a micron (one thousandth of a millimeter). Cellulose nanofibers have been used in a variety of products ranging from ink to transparent displays, but their potential use in cars has been enabled by the "Kyoto Process," under which chemically treated wood fibers are kneaded into plastics while simultaneously being broken down into nanofibers, slashing the cost of production to roughly one-fifth that of other processes. "This is the lowest-cost, highest-performance application for cellulose nanofibers, and that's why we're focusing on its use in auto and aircraft parts," Kyoto University Professor Hiroaki Yano, who is leading the research, told Reuters in an interview. The university, along with auto parts suppliers, are currently developing a prototype car using cellulose nanofiber-based parts to be completed in 2020.

Junkyard Gem: 1986 Mazda 323 DX Hatchback

Mazda built generation after generation of the Familia, starting with the Giugiaro-styled machines of the 1960s. The first Familia that sold well in North America was called the GLC (for "Great Little Car"), and it began life as a rear-wheel-drive cousin to the RX-7 before the Familia went to a front-wheel-drive platform for the 1981 model year. The GLC name stuck around these parts through 1985 — and I've documented a few discarded examples of these now-rare machines during my junkyard travels — before getting the 323 name starting in the 1986 model year. It's no sweat to find 1990s 323s in junkyards, but I've been scouring the car graveyards of the land for the elusive early 323 and, finally, found this moss-encrusted '86 in a San Francisco Bay Area yard. BMW popularized the lower-case-i nomenclature for fuel-injected cars with the first 3-Series back in the 1977 model year, and Mazda wasted no time making "1.6i" badges to tout the futuristic technology under the hood of their low-priced econo-commuter a decade later. At a time when most Civics had carburetors (and the notorious "Map of the Universe" diagram to untangle the underhood vacuum lines), the electronically fuel-injected engine in this car was a major selling point indeed. It wouldn't be many more years before the wretched Subaru Justy was the final carbureted Japanese car available in America, but this 1.6-liter B6 four-cylinder (which evolved into the engine that, flipped 90 degrees, powered the early Miatas) was high-tech stuff for a cheap car in 1986. Just 84 horsepower, but they were clean and reliable horses. In the middle 1980s, the common perception in North America was that you had to buy a Honda or Toyota if you wanted an affordable car that could make it to 200,000 miles. This 323 held together just as well as most Tercels or Civics from 1986. Of course, I've seen a junkyard RX-7 with 393,854 miles, so you just never know. When you see lots of moss and lichens on a car in a Northern California junkyard, you know it spent years — maybe decades — languishing in a shady outdoor spot. Perhaps this car racked up 20,000 miles per year slogging through a harrowing Lodi-to-Sausalito commute, then got parked and forgotten in 1996. We'll never know. With the optional automatic transmission — nearly every early 323 I've seen had the 5-speed manual — this car wouldn't have been much fun to drive. Point A to Point B would have been fine, though.

Living Life Large: Driving $2 million worth of cars in one week

Monterey Car Week has quickly become one of my favorite events of the year. There's something for everyone – classic car shows, modern concepts and new vehicle debuts, auctions, racing, and so much more. From a media perspective, there's also a chance to drive a ton of cars. Many automakers bring their latest wares out to Monterey for us to test during our limited free time, and it's a great opportunity to experience fantastic metal against a gorgeous backdrop. That's exactly what I did this year. Instead of flying into Monterey and being driven around, my journey started in Los Angeles and ended in Napa, and I managed to get behind the wheel of some $2 million worth of new cars. Some were old favorites, and many were new experiences. But looking back, this was one of the best weeks of driving I've had in years. Rather than try to come up with some common arc to tie these cars together, here are my notes on all the cars I tested in California earlier this month, presented in the order in which they were driven. 2016 Mazda CX-3 The CX-3 pictured here isn't the exact one I drove in California, but it's close. The only difference was color – my delivered-to-LAX tester wore Mazda's awesome new Ceramic hue (pictured below on the MX-5 Miata). I used the CX-3 to slum through crummy Los Angeles traffic for two hours on the way out to Santa Barbara, with a quick stop at In-N-Out Burger on the way for good measure. A lot nicer inside than I remember. Everyone praises Mazda for its excellence in engineering and design, but there's a lot to be said for the improvements in overall interior refinement. Quiet, comfortable, and well-equipped; the CX-3 made sitting on the 405 freeway a lot more pleasant. Not all that functional. I had a hard time fitting a week's worth of luggage for two people inside. The cargo area and rear passenger compartment were filled, with only enough room on top to see out the back window. A Honda HR-V would've swallowed all that luggage with plenty of room for more. So good to drive. Not surprising, since this wasn't my first time in the CX-3. I knew this CUV would be good on twisty roads, but on the highway it's really exceptional. Road and wind noise are minimal and the overall ride quality is a comfortable sort of sporty. This is definitely something I could drive every day – it's enjoyable during commuting and entertaining on more interesting roads.