FIA Insitute project manager Andy Mellor said: “The objective is to make severe side impact into a wall or post survivable. To do this, we needed to change the car but in a way that didn’t have a consequence for safety in other types of impact.”

Mellor began work on this project in March 2005, in partnership with the Subaru and Peugot teams. One of the major challenges was coming up with a system which could be integrated by all teams in the current rally cars.

With this in mind, the project group arrived at a formula which breaks down the individual safety components into seven steps. The safety measures include: more space for absorbing energy; a strong supporting seat; strong seat rails; a load spreading door cage; an energy absorber; safety nets and optimized belt anchorage positions.

Mellor said: “Having done the research we knew what changes we needed to do. We then decided to put it into a formula that the teams could manage and which the FIA could regulate and scrutineer. By chopping it up into seven steps it made it very easy to have the technical discussions with the FIA and the teams and work out the delivery programme.”

The first target was to minimize the energy forces on the body of the occupant in the event of a collision. This was achieved through the creation of a 200mm area between the door and the seat, including energy absorbing material and a load spreading door cage.

The next priority was strengthening the driver’s seat to improve head, shoulder and pelvic support. The seat is important because it is the main connection between the driver’s body and the car and also provides the last line of protection should an accident occur.

These measures will be introduced in stages. For the first rally in 2008, the nets, energy absorber, extra space and belt anchorages will be brought in. These represent the major part of the improved protection package. Mid-season will see the introduction of the improved seat and seat-rails. The door cage is planned for 2009, with further testing scheduled for this component.

Much of the research was conducted in co-operation with Peugeot and Prodrive with engineering design by the Subaru World Rally Team.  A high-g sled at Delphi was commissioned for development testing and it demonstrated that a high velocity 70g side impact is, theoretically, totally survivable, with zero injury.

FIA Institute President Sid Watkins led a delegation to the Finland Rally this year to demonstrate the planned improvements to drivers and teams. Following an extremely positive response it is now set for roll out in time from the start of next season.