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Diff and suspension settings are also key. Also I'm not sure of the speeds at Wales, but aero would not play a huge role if it's mainly tight and slow.

Toyota will be changing their aero for 2018....

Unfortunately a bad design can not be saved by a coating or process at the end of the day. If they had hub failures breaking the connection for the lower wishbone at the ballpoint for many rallies...

I also work on chassis components focusing on motorsport for over 12 years :). We use SolidWorks, CREO and Ansys for FEA.

I agree that most "highly" stressed components such as lower control...

And another study from long ago which shows the benefits of shot peening and anodized coatings.

If you don't feel like reading the whole thing go to page 19.
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I know for a fact the TGR hubs are hard anodized after being cryo treated. Shot peening sometimes contaminates the surface.

Some of the other manu's hubs may be shot peened before being hard...

The matte appearance from hard anodizing, not shot peening.

Not sure about Hyundai, but the Toyota hubs are forged monoblock body hubs (similar to AP uses for calipers). The other teams could...

A few images of the Yaris suspension set-up.

The control arms and subframes are works of art. Formed and welded components which are lightweight yet extremely strong.

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The time lost on high speed sections with lower gravel rations could be a big factor too.

Tanak did an amazing job.

I do not think Ti is allowed for the control arms, but is allowed for certain components such as springs etc. The rules still restrict certain components to be made of a specific alloy.

Toyota is using exotic materials for suspension components. Titanium, Magnesium and some crazy hardened steel (same stuff used by Porsche for GT3 crankshafts). The damper, hub and control arms on the...

The right and left coolers have small inlets /outlets. Not large enough for an intercooler. The center end tank is sufficient for an intercooler. I'll try to find a better image.

The Yaris has two radiators with the intercooler in the middle. The intercooler is not in front of the radiators. All three are on the same plane.