Solara Convertible a Development First

The all-new, second-generation Camry Solara convertible enjoyed a unique development process, as it was designed from the onset as a wholly distinct model from the Solara coupe. The drop-top was not engineered as an offshoot of a coupe that would have its roof removed during the manufacturing process.

Toyota Motor Corp. engineers says this strategy helped the auto maker increase markedly the Solara convertible's body rigidity and ensure tight sheet metal tolerances and higher-quality fit for interior pieces, leading the gaps between interior panels to be reduced from 0.06 ins. (1.5 mm) to just 0.02 ins. (0.5 mm).

This is the first time Toyota has developed a convertible in this fashion. Solara was completed in 19 months, the shortest time span for a North American-built Toyota. As Toyota has conditioned the industry to expect, it will introduce the '05 Solara convertible at a lower price than its predecessor.

A high-level Toyota engineering source tells Ward's the concurrent development of distinct coupe and convertible body styles is markedly more expensive initially — but those costs are more than recouped in the convertible's manufacturing process, as well as further down the line with reduced warranty expenses and improved customer satisfaction.