Testing: All-New Opel Mokka on the Road to Production Readiness

• Opel engineers put the finishing touches to next-generation Mokka
• New Opel Mokka up to 120 kilogrammes lighter than previous model
• Chassis and assistance systems set up during winter tests in the Arctic
• All-electric Opel Mokka-e offers engaging drive
• Suspension tuning currently underway at Test Center Rodgau-Dudenhofen
• New Opel Mokka in dealer showrooms in early 2021

All-New Opel Mokka at the Test Center Rodgau-Dudenhofen in Germany

Dynamic, efficient and high quality: these are just a few of the development objectives of the all-new Opel Mokka. With typical precision, German engineers have been putting the finishing touches to the next-generation bestseller. At the Test Center Rodgau-Dudenhofen in Germany, they are currently setting up the new Mokka for optimum acoustic comfort in the interior, excellent driving safety at high speeds and Opel-typical steering and pedal feel. Since February, the Opel experts for chassis, powertrain, electronics and lighting have been using the Arctic winter for the tuning of chassis and assistance systems on frozen lakes and narrow country roads in Swedish Lapland.

Next Opel Mokka generation is a completely new design based on the company's highly efficient CMP multi-energy platform (Common Modular Platform). This modular kit offers maximum flexibility in vehicle development. CMP also allows the use of purely battery-electric drive as well as internal combustion engines. Customer has the choice. Thanks to the use of high-strength steels, the vehicle weight is low and the body stability is high. New Opel Mokka weighs up to 120 kilograms less than the previous model – with almost the same wheelbase and tyre sizes. With the electric Opel Mokka-e, batteries are installed deep in the vehicle floor, which lowers the centre of gravity and at the same time increases torsional rigidity by a further 30 % – excellent prerequisites for dynamic driving. Customers can look forward to a very agile second-generation Opel Mokka, which will be available in dealerships from early 2021. Until then, the testing continues at full speed.

Phase 1: Testing and fine-tuning at Arctic Circle

Opel engineer Gunnar Nees never tires of turning lap after lap on ice. He regularly stops for a few minutes. Reaches for the laptop, reads out measured values, logs every kilometre covered. In the vast Arctic wilderness, it is still freezing cold in March. Exactly the right conditions for orchestrating the harmony between ABS, ESP, assistance systems and the rest of the new Opel Mokka’s chassis.

Eevelopment cars are still hiding behind a green and black camouflage, with 3D-like graphics that blur the vehicle’s contours. Engineer behind the steering wheel has come to the far north to set up the chassis. Like every Opel, new Mokka must respond precisely to steering inputs and give good feedback, be comfortable and at the same time have a firm enough ride. An Opel must not display uncontrolled body movements, for example, when the vehicle is driving over a large bump at medium speed. Opel philosophy calls for safe and relaxing driving on the autobahn. An Opel must remain easily controllable in all situations and be fun to drive at the same time.

These characteristics must be present under all weather conditions everywhere – at the icy Arctic Circle as well as in high summer at the Mediterranean. However, nothing should change in terms of precise handling and consistently good-natured driving behaviour. Parts, components and systems are continuously fine-tuned by the Opel engineers: dampers, springs, steering. In addition, the control software is adapted: for ideal pedal feel when accelerating and braking, for the right amount of steering power assistance and for the interaction between all assistance systems.

Phase 2: High-speed driving on German test tracks

Back in Germany: same test engineer pilots Opel Mokka prototype on home ground at the Rodgau-Dudenhofen Test Center. Karsten Bohle, project coordinator for the second-generation Opel Mokka, joins Gunnar Nees.

“We are all looking forward to seeing New Opel Mokka on the road in customer hands. Test drives are running like clockwork, also because our new baby, with its low weight and compact external dimensions, reacts well to adjustments. Handling and comfort are super. New Opel Mokka is a joy to drive,” said Bohle, “the development work has been great fun.”

Karsten Bohle, project coordinator for the second-generation Opel Mokka

New Opel Mokka is ready to take its final exams at the Test Center. While shaken, ride comfort and interior acoustics must remain unstirred – not even by the torture track. Here, not far from the Opel headquarters in Rüsselsheim, the tracks are replicas of the trickiest road surfaces in Europe. Opel engineers have tested here for decades and built up a huge wealth of experience. Engineers repeatedly adjust springs and dampers, the balance between responsiveness and sporty precision continuously improved. New Opel Mokka features particularly low road noise for optimum acoustic comfort, which the high-quality materials in the interior further increase. Squeaks and rattles are taboo.

Steering and suspension get their Opel “feel” on the Dudenhofen handling course. Two tie rods at the McPherson strut turrets are standard equipment; they provide further stiffness at the front end, adding a touch more precision and agility. New Opel Mokka turns into corners eagerly, is easy to handle at the limit and the assistance systems function perfectly. Then comes the ultimate discipline – the high-speed oval with its steep banking, followed by the long straight. This test demands rock-solid stability at all speeds. In real life, it also results in a huge safety benefit when taking avoidance manoeuvres at lower speeds. Opel engineers only award their seal of approval for the autobahn when they return satisfied from the high-speed oval. New Opel Mokka has already passed this test with flying colours. However, testing, testing and yet more testing will continue until the summer. When New Opel Mokka has achieved production readiness, cars will start rolling off the assembly line at the end of the year.

!NEW! Opel Astra K: Camouflage is the First Step to Success

• Traditional trickery: 30 years of camouflaging and trickery at Opel
• From ‘Fishies’ to ‘Cube’: 3D effect makes debut in fourth generation camouflage foil
• Cover-up better than naked truth: Interior camouflage increasingly important

Fourth generation camouflage foil: Between 60 and 70 sheets of foil are required to completely cover up a compact class car like the new Opel Astra K.

It is a never ending contest: the battle between carmakers and the spy photographers. The one side will do anything in its power to hide their newest creations from the outside world for as long as possible, whereas the other side develops increasingly creative techniques to get a shot of their motorized prey and to get the first photograph of a prototype. For 30 years, Opel has been developing new camouflage foils and artificial add-on components to lead the automotive paparazzi astray. The latest coup of the cover-up team is, amongst others, being used for the new Opel Astra K: The black and white ‘Cube’ camouflage foil. Opel hopes to keep the design and the interior of the newly-developed Astra a secret until the first photographs are released in the upcoming weeks. The new Opel Astra K will be on show in all its beauty for the first time and celebrate its world premiere at the International Motor Show in Frankfurt in September.

Traditional trickery: 30 years of camouflaging and trickery at Opel

The experts have paid special attention to protecting the newly designed fascia, the grille with the distinctive Opel Blitz and the rear from curious eyes. If camouflage expert Andreas Kubis had his way, the new Astra would be covered up completely. However, Astra prototypes can only be distorted to a degree that still allows engineers and test drivers to deliver realistic results for the following production vehicle. And obviously a TÜV safety inspector has to clear the camouflaged vehicle before it is allowed to take to the road. That makes certain things easier for Kubis to accept, the lights for example. “The turn indicators have to be visible from the side,” explains Kubis. Nonetheless, ideally the precise contour of the lights should remain hidden as it is one of the recognition factors and characteristic for every Opel.

For 30 years: Opel has been developing new camouflage foils and artificial add-on components to lead the automotive astray

Kubis, a certified technical manager, has successfully being trying to stay a step ahead of spy photographers since 2012. The 3D effects of ‘Cube’, already frustrating preying eyes during the development phase of the Corsa, only indicate the contours of the new Astra, make them become blurred and confuse onlookers. Between 60 and 70 sheets of foil are required to completely cover up a compact class car like the new Opel Astra. It is stone chip, temperature and UV-resistant. Temperatures ranging from minus 40 degrees to plus 80 degrees Celsius are not a problem. After all, the test drivers in Arjeplog in northern Sweden need to rely on the camouflage in the most adverse weather conditions.

For the first time ever, the experts used an additional special privacy foil for the instruments, center console and infotainment system of the band new Opel Astra K prototype. “The material is well-known from laptops and mobile phones. It prevents the contents of the screen being visible from the side,” explains Kubis. Plastic enclosures and foam flesh simulate the shape of the instruments, whereas the privacy foil can even take on the most powerful zoom lenses.

From Fishies via Wirries to Cube – four generations of camouflage foil

‘Cube’ is already the fourth generation of camouflage foil used by Opel. “Looking back, it is plain to see how colleagues adapted current trends in body construction and turned them into a match camouflage philosophy,” describes Kubis. At the beginning, it was only about covering the rough edges and concealing the headlights behind yellow and red tape. The demands on camouflaging grew continuously as camera technology improved. At the end of the 1980s, camouflaging reached a new level with the front and rear ends also disappearing under tape. “Even the windows were partially covered to obscure characteristic window lines,” says Kubis. The first Opel camouflage foil, with fish-shaped hashes called ‘Fishies’, was used on the Corsa C in 1999. A team of up to three people needed several days to apply the foil to the car back then. Gradually, the camouflage experts padded the foil with plastic and foam components, distorting the vehicle completely. The ‘Flimmies’ pattern, used amongst others for the Astra J in 2009, saw the time required to cover a car shrink to two days per vehicle. But each check had to be applied individually and painstakingly removed later. Screen printing technology used for the third-generation ‘Wirries’, used from 2011 to 2013, saved the experts up to a day of work. The foil could be applied in one piece and removed if required.

Test drivers rule: Camouflage is part of the job

Opel has been camouflaging the interior of its new cars since 2008 and obviously there has been developments in this sector too. In the past, hand-stitched artificial leather covers with Velcro were used to cover the instrument panel and the dashboard. These days the experts rely on a much lighter mesh fabric known from backpacks which allows for the individual components to be covered separately. Air vents, the handbrake and other important buttons such as the hazard light button need to remain uncovered when on the road. A special lamination seals up the rear and side windows while at the same time allowing the driver to see out. To this day, test drivers and engineers follow a simple rule, especially when parking the car: cover up the instruments and protect the interior from preying eyes.

Camouflage is good but a trick is sometimes better

New Opel ADAM S - Prototype with ‘Driver training’ lettering.

When looking to the animal kingdom it becomes apparent that camouflage is good, but a trick can be (even) better. The new Opel ADAM S with its eye-catching wheels and the distinctive spoiler posed a real challenge for Kubis and his team. “We didn’t want to make the first prototype even more attention-grabbing. That is why we didn’t camouflage the Opel ADAM S. Instead, we make it look like a training car,” says Kubis. The lettering ‘Driver training’ and some sporty black and yellow stripes did the trick and the paparazzi lost interest. The battle was won – at least until the next round.

New Opel ADAM S - Prototype with ‘Driver training’ lettering.