Media Platforms Design TeamThe 2013 Mercedes-Benz SL550 is loaded with new aluminum underpinnings that help shave 242 pounds from its chassis. And while large bits like the engine bulkhead– the single biggest piece of die-cast aluminum in the production auto biz– certainly play their part in weight savings, there are loads of other unsung details, as well.Take the SL’s floorboard. Replacing the simple steel sheet found in its predecessor, the new application uses a thin-wall, double-plated hollow profile aluminum fused using a friction stir welding technique. Not only is it lighter and stiffer than before, the structure incorporates varying wall thickness which enables stronger construction where necessary, while maximizing weight savings where it counts.Combined with one-piece carpeting and thicker foam backing for improved road noise insulation, Benz’s new floorboard design is a structural element unlikely to get much attention. But it’s just as deserving as the rest of this two-seater’s unseen efforts to create a lighter, nimbler, and more fuel efficient roadster.
