MIAMI GARDENS, Fla. — It might sound like something straight out of a child`s fantasy: constructing a fully functional, life-sized Formula 1 car using nearly 400,000 Lego bricks, then driving it around the Miami Grand Prix track.
This incredible concept emerged last year during a visit by Lego`s senior leadership to their model factory in Kladno, Czech Republic. While brainstorming ways to promote Lego`s new partnership with F1, the team had a groundbreaking idea.
“We were discussing and brainstorming together, asking, `What could we create with F1 that would be absolutely epic and unlike anything we`ve attempted before?`” shared Julia Goldin, Chief Product and Marketing Officer at the Lego Group, speaking in Miami. “The team`s response was, `Well, how about building full-size cars? And what if they were actually drivable?` It took some time, because while it`s a fantastic idea, turning it into reality is challenging. But that was the starting point of the process.”
Senior designer Jonathan Jurion and engineering manager specialist Martin Šmida were tasked with making this ambitious vision a reality. Their objective was to faithfully recreate life-sized versions of the latest Lego Speed Champions F1 car models, ensuring they not only matched the appearance of the retail product but were also capable of completing the entire 3.3-mile lap of the Miami International Autodrome during the customary prerace drivers` parade.
Lego has extensive experience building precise life-size models for its theme parks. However, prior to this F1 project, only one of their full-scale vehicle models had ever been drivable. This is partly due to the inherent fragility of 400,000 Lego bricks, even when reinforced with special construction glue. Additionally, a drivable vehicle requires a robust steel-frame chassis, an electric powertrain, hydraulic braking, and a power steering system.
The Miami project introduced another specific challenge: only one car would be built per team. This meant each model needed to be spacious enough to comfortably accommodate two F1 drivers.
Speaking from Kladno earlier in the year, Jurion held a small Speed Champions model as he described the scaling process, transforming the 1/30th scale toy into a life-size construction.
“We began with this small build, modifying it slightly to fit two minifigures,” he explained. “Obviously, a minifigure`s proportions aren`t the same as a human`s, but it provided a starting point. We then took that design and scaled it up. So, the finished life-size car is exactly 30 times larger than the original model available in stores. Our process involved going piece by piece, designing each component to make it look as true to the original as possible.”
To maintain the correct proportions while accommodating two drivers, the cockpit area was extended, allowing one driver to sit directly behind the other, tandem style. (It will be fascinating to see which driver from each team chooses the front seat, offering a glimpse into teammate dynamics).
“Our seating arrangement was actually inspired by two-person airplane designs, with occupants sitting one behind the other,” Jurion commented. “They will be a bit snug inside, but we made sure to create the maximum possible space for them.”
Šmida, who oversaw the engineering of the car`s mechanical components, highlighted an additional feature designed to enhance the comfort for the driver at the controls.
“We have space for two, and since driver heights vary, we incorporated adjustable pedals,” he said. “These pedals can be moved 10 centimeters forward or backward.”
Unlike standard Lego kits, there was no predefined instruction manual for this project. Working with his design team, Jurion utilized specialized software to plan the brick assembly layer by layer, crafting the complex shapes needed to mimic F1 bodywork while also incorporating specific team sponsor logos using Lego bricks.
“We build in the software just as you would build with bricks physically, but on a much larger scale,” Jurion explained. “We lay down layers sequentially, similar to constructing a building. Once the design is complete, we create a detailed manual, like those found in retail sets, for our builders. They follow this guide layer by layer, gluing the bricks together until the impressive cars take shape.”
“The models are built in separate sections – for instance, the engine cover is one part, the halo another, the nose a third,” he added. “These components are then assembled together.”
The only visible parts of the construction not made from genuine Lego bricks are the wheels and tires, which were borrowed from the F1 teams and F1`s tire supplier, Pirelli. Even the steering wheel features an outer casing constructed from Lego, complete with replica switches and dials designed to look like the real F1 wheel.
The 400,000 bricks alone weigh 1,000 kilograms (about 2,200 pounds). The non-Lego components, including the structural steel chassis supporting the build, add another 500 kg (about 1,100 pounds). This brings the total weight to 1,500 kg (about 3,300 pounds) – nearly double the weight of an actual F1 car.
Šmida`s primary responsibility was ensuring the finished cars were robust enough to complete the parade lap under their own power. The chassis needed to be strong enough to support over a ton of bricks and also house an electric motor and drivetrain capable of propelling the entire structure to a maximum speed of just under 13 mph. This speed is comparable to the flatbed trucks typically used for driver parades at other circuits.
Overall, the project involved a staggering 3,000 hours of development and an additional 19,000 hours of assembly time to construct all 10 cars.
Following the Miami drivers` parade, these unique models are scheduled for a worldwide tour, allowing Lego and F1 enthusiasts alike to admire the craftsmanship. Perhaps the most challenging task now for Goldin and her leadership team is devising a way to surpass this achievement for Lego`s next F1-related project.
“That`s the question everyone is asking,” Goldin admitted. “And we`re asking it ourselves.”
“However,” she continued, “one of our core principles is to never let our imagination be limited by what is considered achievable. Our goal is always to make the impossible possible. I am confident that the ingenuity of our teams will lead to another, even more ambitious idea.”
Dominic Ashworth