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The Sweet Rotation of History

FEATURE BY MAX NOBLE
12/07/2018

Well dear reader, with Fernando winning Le Mans with Toyota, the second Japanese manufacturer to manage this commendable triumph, now is a perfect time to cast a long look over the shoulder, back over half a century, to catch a glimpse of engineering inventiveness that was the genesis of a very particular motoring legend that would eventually be crowned by Mazda winning the 1991 edition of Le Mans in fine style.

This is a tale of engineering inventiveness, persistence, and an object lesson in how the FIA reacts to innovation...

So settle back with a favoured flavour of tea, or if the sun is over the yard arm in your nook of this wonderful planet, possibly a G&T or some other suitable relaxant, and walk with me awhile into this fascinating tale.

It was 1st February 1957 when Doctor Walter Frode successfully started the first Wankel engine. A most remarkable engine designed by Felix Wankel who had the impassioned idea of removing reciprocating parts from the internal combustion engine to make it simpler, and, he hoped, as a result, more compact and reliable.

Wankel was not a trained engineer. He had a love of mechanical devices, and had previously expended significant energy cataloguing the rotary mechanical concepts of previous ages. So it was that still in the shadow of World War One, the young Felix came to Heidelberg. Not to study at the famed University, but to work for a local bookseller. Here, in the solitude of the storeroom Felix honed his technical drawing skills, while completing technical training via correspondence. Over the following years his reputation slowly grew, but it was work on sealing reciprocating piston engines that gained Felix engineering respect, not wild ideas for revolutionary engine concepts. In 1936 Felix moved to Berlin and commenced work for the Aviation Ministry's Central Research Establishment. His transformation into respected engineer thus commencing just prior to the Second World War.

Time flowed during a dark period in history, with an eventual arrival in December 1951, and we find Felix joining NSU (Neckarsulmer Strickmachinen Union) a respected motorcycle builder. Here he gently pushed his idea for a rotary engine, and was just as gently pushed back. By 1954 Felix had waited long enough, he gave NSU an ultimatum, develop my engine, or I'm leaving. Thankfully they did not call his bluff.

The birth of the rotary was far from easy. NSU hovered on the edge of financial ruin, and a major cash injection from Curtis-Wright, an American aircraft engine manufacturer for the rights to develop the engine, was required to keep rotary development moving. The rotary appeared in a number of experimental American cars, including Ford Mustangs, and in later years, even a Citroen GS Birotor, but the most lasting early fame came from the NSU Ro80 running a rotary refined by NSU's Dr. Frode. Rather than elation at this success Felix felt betrayed as his desires for an elegant, smooth running pure rotary, he felt, had not been met.

The Ro80 was produced from 1967 to 1977, with a little over 37,000 being built. By this time NSU had been subsumed into the Volkswagen empire via a merger with Auto Union. Then came the first Japanese interest from Nissan, who took a Wankel license in 1970 for production of engines from 30 to 230hp. A prototype was proudly displayed at the 1972 Tokyo motor show, with a promise of a lithe sports car for 1974. Then, for the first time, the motoring world felt the might of the OPEC empire, and spiking oil prices drove a stake through the beating heart of interest in the exciting, but overly thirsty rotary concept. Nissan permanently cancelled the rotary project.

Toyota meanwhile spent time accessing the concept from afar, and when the oil crisis hit simply ceased investigation with little lost.

The Americans had not been idle, GM was very active in researching rotaries even to the point of displaying a twin-rotor Corvette at the 1973 Frankfurt motor show. Ford meanwhile was spending money more to shadow GM rather than due to any deep company belief that rotaries were the future. Another stunning concept car, the Corvette four rotor, was shown at the Paris motor show, and it was rumoured the 1975 Chevrolet Monza would have a rotary option.

Then, just as it appeared Felix's rotary dream was going mainstream, the US introduced tough new emissions laws to be phased in over the coming production years. Even after the millions they had spent GM looked at the emissions standards set to be introduced for 1977, and worried about their regular engines meeting requirements, let alone the still mostly experimental rotary. Felix's dream was stamped out at GM with the engine again failing to see the light of day in full production.

Finally only one company kept faith with the concept and retained an unshakable determination to bring it to market. The Japanese company Toyo Kogyo. Company president Tsuneji Matsuda personally instructed Kenichi Yamamoto to investigate the engine. Engineers toiled, markets developed, and Toyo Kogyo became Mazda. Their first car was offered to the public in 1960. By mid-1964 this tiny company had over 180 staff focused on the rotary concept. It soon became the case that this internal project was simply so big that failure of the rotary engine would take the company with it.

So it was that May 1967 saw the first Mazda Cosmo roll off the production line. Under the neat, low, bonnet line was a twin rotor, dual side-ported engine breathing deeply through a Hitachi four-barrel carburettor. The tragically fragile apex seals of the NSU rotarys had been addressed by the adoption of new exotic materials, based around a Carbon-aluminium mix, rather than the original cast iron. Less than a decade after presenting their first modest car, the R360, here was quietly respectful Mazda presenting a rotary engine sports car to the world. With a hint of Ford Thunderbird to some angles from the outside, and a clear homage to British sports cars on the inside, down to a clean uncluttered dash, and a three spoke wooden wheel, the two door coupe was a fitting sports car home for Japan's production rotary. Over the next five years 1,519 Cosmos were produced. A tiny number, each representing a loss for the company, but it achieved its wider aim of introducing the world to Mazda as a serious carmaker.

1970 and Mazda founded its American headquarters in Seattle, Washington state. The modest first shipment for sale being 380 small cars. Back in Japan Mazda dealers were bogged down in uncleared inventory. An engineer tasked with recasting Mazda products in the public mind was Akio Uchiyama. 1975 found him working near Suzuka. He became convinced that a rotary powered true sports car was the answer to refreshing Mazda in the public mind. At the same time Sinpei Hanaoka, a former banker and now a Mazda board member, toured America and came to the same conclusion to inject energy to the American market. Mazda needed a rotary powered sports car to create a lasting image in the public mind of a progressive, inventive, capable carmaker.

So it was that yet more engineering determination was poured into the Rotary concept. The result was that in early 1978 a new delicate, slim-nosed sports car started rolling down the Mazda production lines for a 1979 model year launch. Now the success of Mazda and the rotary were completely linked. If this incarnation of the rotary failed it was likely that after the time, money, and focus expended Mazda would vanish with it.

The World welcomed the RX-7 with open arms. Slightly shorter than a contemporary Datsun 280Z, but with a longer wheelbase, and with a "front mid-engined" layout giving a near perfect 50/50 weight distribution front to rear, thanks to the compact size of the rotary, it was a remarkable creation for a carmaker that had only presented its first production car for sale less than twenty years previously.

Californian tuning house Racing Beat promptly set a new class record on the Bonneville salt flats in 1979, and Mazda as a racing house was on its way in the USA. Racing Beat would repeat this feat many times, each time proving to the "you cannot beat cubic inches" American market that a crazy-spinning rotary could indeed do just that.

The second occasion of Racing Beat record breaking was in 1986, once more on the Salt Flats. But by this time Mazda had generated a firm following in sports car racing. In 1986 RX-7's owned the IMSA GTU class.

In fact by the mid-1980's the RX-7 was the car to beat in a number of classes. Jim Downing took the GTU title in 1982. Jack Baldwin in 1984, and 1985. An RX-7 then won the 1986 Daytona, while Tom Kendal would win the GTU Driver's championship in 1987.

Victories came in GTO, SCCA, GT-2, but not the championship success seen in GTU. All this American success was great, and mirrored by sporting success back in Japan, but Europe was still not in love with the rotary concept. Mazda wanted a headlining European win to grab the attention of the European sports car world. What better way than with an attempt on Le Mans?

While not designated an RX-7, as the American track cars were, the Mazda 787 and 787B were bespoke prototype track racers based off years of rotary racing experience.

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READERS COMMENTS

 

1. Posted by Max Noble, 16/07/2018 6:10

"@NS Biker - technical correctness noted!

Agree many types of fuel can be accommodated with the right combustion physics.

:-) ... no matter how deep one goes on a topic there is always that “...one last tale to be told...” so I agree I’d have to approach any C111 story with caution!

A complete history of Liberty Media contributions to the advancement of F1 racing might, however, be shorter... :-)"

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2. Posted by NS Biker, 15/07/2018 5:05

"Not to be picky ... but, engines don't run on Liquified Natural Gas, this is a storage system. Cryogenic and low pressure.
Westport Innovations has been developing a direct injection diesel technology, both OEM and retrofit. This is basically using cryogenic liquid storage and high pressure vaporized injection. https://www.westport.com/
You can run any IC engine on natural gas (in the vapor form). Lots of people do and have, going back over a hundred years.
Rudolf Diesel did a load of work on amonia as a fuel. Another self vaporizing pressurized liquid fuel. Yep, a real headache to deal with.
Yes, for any "dry" fuel system in a rotary you may need some additional lubrication. I understood that the Mazda early versions, had an oil injection system (similar to 2-stroke engines). Not sure about the European developments, Mercedes, Audi, Sachs and likely others.
Max .... careful, this is the sort of topic that could have you researching and typing for ages.
Maybe a picture or two and some performance data for a C111 will have the techies going nuts.
Thanks."

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3. Posted by Max Noble, 13/07/2018 6:29

"@ClarkwasGod and @NS Biker - thanks for positive feedback!
Apologies to regular readers for a slight delay in transmission....! Hopefully full service has been resumed!

It was tricky knowing what to leave out the story as so many people played a part in this remarkable engineering story and the Le Mans win!

Yes indeed! Forgot they were so darn noisy! Good point. :-)

I think they would might have trouble combusting LNG... and Apex seal lubrication might become an issue with such a dry fuel...??

Ah! The C111... ok... I’ll reflect on blowing more dust off the past!

Cheers!"

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4. Posted by NS Biker, 13/07/2018 5:55

"Minor piece of history that I was looking forward to as I read this was some background on the Mercedes C111.
Not to stress, awesome summary. Love it.
Thanks Max .... again.
Zoom .... Zoom...!"

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5. Posted by ClarkwasGod, 12/07/2018 19:26

"Another good one, Sir! Brought back some good memories. I love it when a "minnow" smacks the big players right in the kisser!!!

They were so NOISY!!!! (I recall that Weidler went out for one stint and forgot to put his earplugs in - the damage to his hearing effectively ended his racing career, I think).

Maybe mention should have been made of Nigel Stroud who designed the 757 - 787B series for them (Mazda)? Seems that furniture design and racing car design have similar attractions, given that both he, and Gordon Murray have done the same thing.

I wonder whether it would be possible to convert a rotary to run on LNG fuel - that would overcome the pollution aspect, I would think."

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