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Roadster

Product

Overview

A roadster is a two-seat open sports car whose whole design serves handling and driver involvement rather than space, comfort, or speed in a straight line. The guiding principle is low weight: a light car turns, stops, and changes direction more eagerly than a heavy one, and it can do so with a modest engine. Everything about a roadster, from the structure to the trim to the roof, is chosen to keep mass down and the centre of gravity low. The body is open, with a simple top that folds by hand.

The car is built around a light Body Structure carrying the Powertrain, the Suspension & Brakes, the Folding Top, and a minimal Cockpit, with pared-down Electrical System, Fuel System, and Cooling System systems. The contrast with a luxury convertible is deliberate: where that car adds weight to recover refinement, a roadster sheds it to sharpen response.

Structure

The Body Structure is the heart of the concept. Rather than a steel unibody, many roadsters use a Backbone Frame, a central spine bonded from aluminium extrusions, with lightweight Composite Clamshell panels forming the front and rear bodywork. This keeps the structure stiff for its weight, which matters in an open car that cannot use a roof for rigidity. The Lightweight Doors save weight with Manual Window Winder winders instead of motors, and even the Windscreen Frame is a cast magnesium part that doubles as the anchor for the roof latch.

Powertrain

The Powertrain favours a light, responsive Four-Cylinder Engine, usually a four-cylinder mounted low and either ahead of or behind the cockpit to keep weight central. An all-alloy All-Alloy Block and, on sharper versions, Individual Throttle Bodies throttle bodies give crisp response and a willingness to rev. Drive goes to the rear wheels through a Manual Gearbox, a close-ratio six-speed manual with a Short-Throw Shifter for quick, mechanical gear changes, then through a limited-slip Open Differential that helps put power down out of corners. A lightweight Exhaust System with a tubular Tubular Header frees a little power and gives the car its voice.

Suspension and steering

Handling is the point, so the Suspension & Brakes uses double-wishbone geometry at all four corners, which keeps the tyres square to the road through roll and travel. Springs and dampers are tuned firm, and Anti-Roll Bars limit lean. The Light Steering Rack is a quick-ratio rack with little or no power assistance, so the driver feels the front tyres directly. Brakes are discs at each corner, sized to the car's low weight rather than to brute power.

Roof

In keeping with the lightweight ethos, the Folding Top is deliberately simple. A single-piece Top Fabric stretches over a counterbalanced Manual Top Frame that the driver can raise or fold by hand in a few seconds, secured by one Centre Header Latch at the windscreen. There is no heavy hydraulic mechanism, no powered hard top: the manual top weighs a fraction of a powered one and is part of why the car stays light.

Cockpit and use

The Cockpit is a snug two-seat cockpit with light Bucket Seats and a Minimal Dashboard carrying just the essential instruments and Toggle Switches. Base cars often omit a full climate system to save weight, and the Electrical System system runs only a handful of control units and a Lightweight Battery. The Cooling System system adds a Engine Oil Cooler for cars used on track.

Roadsters range from affordable lightweight models that prize balance over power to high-end sports cars, but the formula is consistent: two seats, an open top, rear-wheel drive, and the lowest weight the maker can achieve at the price. They are bought by drivers who value the feel of a car at moderate speeds on a good road, where a light, responsive car rewards more than a heavy, powerful one. The type traces back to the earliest open sports cars and remains a distinct corner of the market.

The weight argument

Every gram a roadster carries works against its purpose, so the engineering is a running fight against mass. The Backbone Frame uses bonded aluminium because steel of the same stiffness would weigh more, and the Composite Clamshell panels are lighter than stamped steel. Small choices add up: a Manual Window Winder saves the weight of a motor and regulator, a Lightweight Battery saves several kilograms over a conventional one, and a base car may omit a full climate system entirely. Light weight pays off everywhere at once. A lighter car needs smaller brakes, a smaller engine for the same performance, lighter suspension, and less fuel, and each of those reductions removes still more weight. This is why a well-judged roadster can feel quick and agile with an engine that would seem modest in a heavier car.

Driving feel and the open cockpit

The reward for the weight discipline is feel. With low mass, a near 50:50 balance, double-wishbone Suspension & Brakes at every corner, and the direct Light Steering Rack, the car responds immediately to inputs and tells the driver clearly what the tyres are doing. The open cockpit adds to the experience rather than just the styling: with the Folding Top folded, the driver sits in the airflow and hears the Exhaust System directly, which makes moderate speeds feel involving. The Bucket Seats sit the occupants low in the structure, keeping the centre of gravity down and adding to the sense of being part of the machine. None of this depends on outright power, which is why the roadster remains a distinct format even as engines elsewhere grow larger: its appeal is the directness that low weight and an open body provide.

Roadster parts and their functions

9 top-level parts · 655 parts in total · full bill of materials below
Roadster parts diagram: 1 powertrain, 2 body structure, 3 suspension & brakes, 4 folding top, 5 cockpit, 6 electrical system, 7 fuel system, 8 cooling system, 9 wheel assembly. 655 parts in 9 top-level items.
Roadster parts diagram. Numbers match the table below; each box is one top-level part or assembly with what it contains.
#PartQtyWhat it does
1 Powertrain 6 parts 1× Mid or front engine, RWD
2 Body Structure 6 parts 1× Lightweight body structure
3 Suspension & Brakes 6 parts 1× Sport suspension and brakes
4 Folding Top 5 parts 1× Manual folding top
5 Cockpit 5 parts 1× Two-seat cockpit
6 Electrical System 5 parts 1× Minimal wiring set
7 Fuel System 5 parts 1× Tank and delivery
8 Cooling System 5 parts 1× Engine thermal management
9 Wheel Assembly 5 parts 4× Lightweight wheels

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Build & assembly graph

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Bill of materials for Roadster

9 top-level lines · 139 rows shown · 655 parts total · indented to 3 levels
# Item / sub-assembly Part no. Qty/assy Ext. qty Parts Type
1 Powertrain 6 parts roadster-car-powertrain 1× 1 67 assembly
1.1 Four-Cylinder Engine 7 parts roadster-car-engine 1× 1 14 assembly
1.1.1 All-Alloy Block roadster-car-alloy-block 1× 1 · part
1.1.2 DOHC Cylinder Head coupe-car-cylinder-head 1× 1 · part
1.1.3 Piston hatchback-car-piston 4× 4 · part
1.1.4 Crankshaft hatchback-car-crankshaft 1× 1 · part
1.1.5 Camshaft hatchback-car-camshaft 2× 2 · part
1.1.6 Spark Plug spark-plug 4× 4 · part
1.1.7 Individual Throttle Bodies roadster-car-itb 1× 1 · part
1.2 Manual Gearbox 7 parts roadster-car-gearbox 1× 1 28 assembly
1.2.1 Gearbox Housing gearbox-housing 1× 1 · part
1.2.2 Helical Gear Pair gear-pair 6× 6 · part
1.2.3 Synchroniser Ring hatchback-car-synchro 6× 6 · part
1.2.4 Clutch Assembly 5 parts + deeper › hatchback-car-clutch 1× 1 5 assembly
1.2.5 Short-Throw Shifter roadster-car-short-shifter 1× 1 · part
1.2.6 Ball Bearing ball-bearing 6× 6 · part
1.2.7 Oil Seal oil-seal 3× 3 · part
1.3 Propeller Shaft 3 parts coupe-car-prop-shaft 1× 1 5 assembly
1.3.1 Shaft Tube coupe-car-shaft-tube 2× 2 · part
1.3.2 Universal Joint coupe-car-universal-joint 2× 2 · part
1.3.3 Centre Support Bearing coupe-car-centre-bearing 1× 1 · part
1.4 Open Differential 4 parts differential 1× 1 6 assembly
1.4.1 Differential Case diff-case 1× 1 · part
1.4.2 Side Gear side-gear 2× 2 · part
1.4.3 Pinion Gear pinion-gear 2× 2 · part
1.4.4 Cross Pin cross-pin 1× 1 · part
1.5 Rear Axle Shaft 3 parts coupe-car-axle-shaft 2× 2 5 assembly
1.5.1 CV Joint hatchback-car-cv-joint 2× 4 · part
1.5.2 Shaft Bar hatchback-car-shaft-bar 1× 2 · part
1.5.3 CV Boot hatchback-car-cv-boot 2× 4 · part
1.6 Exhaust System 4 parts roadster-car-exhaust 1× 1 4 assembly
1.6.1 Tubular Header roadster-car-header 1× 1 · part
1.6.2 Catalytic Converter hatchback-car-catalytic-converter 1× 1 · part
1.6.3 Sport Muffler roadster-car-sport-muffler 1× 1 · part
1.6.4 Exhaust Pipe hatchback-car-exhaust-pipe 1× 1 · part
2 Body Structure 6 parts roadster-car-chassis-frame 1× 1 21 assembly
2.1 Backbone Frame roadster-car-backbone-frame 1× 1 · part
2.2 Composite Clamshell roadster-car-composite-clamshell 2× 2 · part
2.3 Lightweight Door 5 parts roadster-car-door 2× 2 5 assembly
2.3.1 Door Shell door-shell 1× 2 · part
2.3.2 Manual Window Winder roadster-car-manual-window 1× 2 · part
2.3.3 Door Glass door-glass 1× 2 · part
2.3.4 Door Latch door-latch 1× 2 · part
2.3.5 Side Mirror side-mirror 1× 2 · part
2.4 Windshield windshield 1× 1 · part
2.5 Windscreen Frame roadster-car-windscreen-frame 1× 1 · part
2.6 Bumper Cover 3 parts hatchback-car-bumper 2× 2 3 assembly
2.6.1 Bumper Skin hatchback-car-bumper-skin 1× 2 · part
2.6.2 Crash Beam hatchback-car-crash-beam 1× 2 · part
2.6.3 Energy Absorber Foam hatchback-car-foam-absorber 1× 2 · part
3 Suspension & Brakes 6 parts roadster-car-suspension 1× 1 106 assembly
3.1 Double-Wishbone Corner 5 parts coupe-car-front-wishbone 2× 2 16 assembly
3.1.1 Coil Spring coil-spring 1× 2 · part
3.1.2 Adaptive Damper 4 parts + deeper › coupe-car-adaptive-damper 1× 2 4 assembly
3.1.3 Control Arm control-arm 2× 4 · part
3.1.4 Ball Joint ball-joint 2× 4 · part
3.1.5 Wheel Hub 3 parts + deeper › wheel-hub 1× 2 7 assembly
3.2 Rear Wishbone Corner 5 parts roadster-car-rear-wishbone 2× 2 16 assembly
3.2.1 Coil Spring coil-spring 1× 2 · part
3.2.2 Shock Absorber 4 parts + deeper › shock-absorber 1× 2 4 assembly
3.2.3 Control Arm control-arm 2× 4 · part
3.2.4 Ball Joint ball-joint 2× 4 · part
3.2.5 Wheel Hub 3 parts + deeper › wheel-hub 1× 2 7 assembly
3.3 Light Steering Rack 3 parts roadster-car-steering 1× 1 4 assembly
3.3.1 Rack Housing rack-housing 1× 1 · part
3.3.2 Rack & Pinion rack-pinion 1× 1 · part
3.3.3 Tie Rod tie-rod 2× 2 · part
3.4 Front Performance Brake 4 parts coupe-car-front-brake 2× 2 9 assembly
3.4.1 Brake Caliper 4 parts + deeper › brake-caliper 1× 2 6 assembly
3.4.2 Two-Piece Vented Disc coupe-car-vented-disc 1× 2 · part
3.4.3 Brake Pad Set brake-pad-set 1× 2 · part
3.4.4 Brake Hose brake-hose 1× 2 · part
3.5 Rear Disc Brake 4 parts roadster-car-rear-brake 2× 2 9 assembly
3.5.1 Brake Caliper 4 parts + deeper › brake-caliper 1× 2 6 assembly
3.5.2 Brake Disc (rotor) brake-disc 1× 2 · part
3.5.3 Brake Pad Set brake-pad-set 1× 2 · part
3.5.4 Brake Hose brake-hose 1× 2 · part
3.6 Anti-Roll Bar coupe-car-anti-roll-bar 2× 2 · part
4 Folding Top 5 parts roadster-car-roof 1× 1 5 assembly
4.1 Top Fabric roadster-car-top-fabric 1× 1 · part
4.2 Manual Top Frame roadster-car-top-frame 1× 1 · part
4.3 Centre Header Latch roadster-car-header-latch 1× 1 · part
4.4 Plastic Rear Window roadster-car-rear-window 1× 1 · part
4.5 Tonneau Boot Cover roadster-car-top-cover 1× 1 · part
5 Cockpit 5 parts roadster-car-interior 1× 1 22 assembly
5.1 Bucket Seat 3 parts roadster-car-bucket-seat 2× 2 4 assembly
5.1.1 Seat Frame seat-frame 1× 2 · part
5.1.2 Seat Foam seat-foam 2× 4 · part
5.1.3 Seat Cover seat-cover 1× 2 · part
5.2 Minimal Dashboard 3 parts roadster-car-minimal-dash 1× 1 8 assembly
5.2.1 Instrument Cluster instrument-cluster 1× 1 · part
5.2.2 Toggle Switch roadster-car-toggle-switch 6× 6 · part
5.2.3 Dashboard Trim dash-trim 1× 1 · part
5.3 Steering Wheel 3 parts steering-wheel 1× 1 4 assembly
5.3.1 Wheel Rim Core wheel-rim-core 1× 1 · part
5.3.2 Airbag Module airbag-module 1× 1 · part
5.3.3 Steering Control Switch control-switches 2× 2 · part
5.4 Aluminium Shift Knob roadster-car-shift-knob 1× 1 · part
5.5 Floor Carpet carpet 1× 1 · part
6 Electrical System 5 parts roadster-car-electrical 1× 1 383 assembly
6.1 Electronic Control Unit 4 parts ecu 3× 3 93 assembly
6.1.1 Bare PCB pcb-bare 1× 3 · part
6.1.2 Microcontroller mcu 1× 3 · part
6.1.3 CAN Transceiver can-transceiver 1× 3 · part
6.1.4 SMD Passive (R/C/L) smd-passives 90× 270 · part
6.2 Lightweight Battery roadster-car-light-battery 1× 1 · part
6.3 LV Wiring Harness 4 parts lv-harness 1× 1 54 assembly
6.3.1 Wire Bundle wire-bundle 1× 1 · part
6.3.2 Connector connector 40× 40 · part
6.3.3 Fuse Box fuse-box 1× 1 · part
6.3.4 Relay relay 12× 12 · part
6.4 Alternator 4 parts hatchback-car-alternator 1× 1 25 assembly
6.4.1 Stator Assembly 3 parts + deeper › stator-assembly 1× 1 3 assembly
6.4.2 Rotor Assembly 4 parts + deeper › rotor-assembly 1× 1 19 assembly
6.4.3 Rectifier Bridge hatchback-car-rectifier 1× 1 · part
6.4.4 Ball Bearing ball-bearing 2× 2 · part
6.5 Starter Motor 4 parts hatchback-car-starter 1× 1 24 assembly
6.5.1 Stator Assembly 3 parts + deeper › stator-assembly 1× 1 3 assembly
6.5.2 Rotor Assembly 4 parts + deeper › rotor-assembly 1× 1 19 assembly
6.5.3 Starter Solenoid hatchback-car-solenoid 1× 1 · part
6.5.4 Pinion Drive hatchback-car-pinion-drive 1× 1 · part
7 Fuel System 5 parts roadster-car-fuel-system 1× 1 8 assembly
7.1 Fuel Tank hatchback-car-fuel-tank 1× 1 · part
7.2 In-Tank Fuel Pump hatchback-car-fuel-pump 1× 1 · part
7.3 Fuel Injector hatchback-car-injector 4× 4 · part
7.4 Fuel Rail hatchback-car-fuel-rail 1× 1 · part
7.5 Fuel Filter hatchback-car-fuel-filter 1× 1 · part
8 Cooling System 5 parts roadster-car-cooling 1× 1 7 assembly
8.1 Radiator radiator 1× 1 · part
8.2 Engine Oil Cooler station-wagon-oil-cooler 1× 1 · part
8.3 Water Pump hatchback-car-water-pump 1× 1 · part
8.4 Cooling Fan hatchback-car-cooling-fan 1× 1 · part
8.5 Coolant Hose coolant-hose 3× 3 · part
9 Wheel Assembly 5 parts wheel-assembly 4× 4 9 assembly
9.1 Alloy Wheel alloy-wheel 1× 4 · part
9.2 Tire tire 1× 4 · part
9.3 TPMS Sensor tpms-sensor 1× 4 · part
9.4 Lug Nut lug-nut 5× 20 · part
9.5 Valve Stem valve-stem 1× 4 · part

Sourcing: possible vendors

Browse the supplier directory → Prices, MOQ, and lead times are algorithmic estimates, not quotes, and not claims about these companies. Company mappings are curated by keyword; est. price band $8k–$90k. How estimates work
VendorHQSpecialtyMOQLead time
🇯🇵Toyota
global.toyota ↗
Toyota City, JP Automaker made to order 16–28 wks
volkswagen-group.com ↗ Wolfsburg, DE Automaker made to order 16–28 wks
gm.com ↗ Detroit, US Automaker made to order 16–28 wks
hyundai.com ↗ Seoul, KR Automaker made to order 16–28 wks
🇨🇳BYD
byd.com ↗
Shenzhen, CN EV & battery manufacturer made to order 16–28 wks

1,024-word article