One last question Is the 160 only available in the sport form? And are the sports the ones with the dreadful suspension and 18inch wheels
The 165 is only available on the 3 Sport (there's a Sport [120PS] and a Sport 165 [165PS]). The Mazda6 Sport is only available in 165 PS form for the petrol (145PS form for lower spec models, roughly similar performance as the 3's 120PS).
I don't think there's much, if any, difference in the suspension set up between models as far as I'm aware - its just that the combo of the larger 18in wheels and lower profile tyres (same overall diameter of the 16in tyre, but a bit wider) on ALL Sport models means that the ride is firmer, especially on poorly surfaced roads, over speed humps, etc, particularly after the newness of the car and its tyres starts to fade after the first 6-12 months/5k miles or so. As regards the brakes, I'm not sure if they are any different and thus may only be able to accommodate 18in wheels on the Sport/Sport 165 - best to check with your local dealer.
The ride quality is always going to be a matter of contention, as its very subjective (unless its absolutely terrible, which is isn't) because it depends on a) the view of what is a decent ride and what isn't by the person testing the car (often affected by what they have been driving before, whether they have back problems, their style of driving, etc) and b) the conditions of the road surface they are testing it on, as well as the age/mileage of the car tested.
This is why I always try and test drive both a new car and a used one to see how it will fair after a year or two (or so) as the suspension and tyres begin to wear. I always try and test drive the car on the type of roads (condition and configuration) that I will be mainly driving on should I buy it, and will take it out for at least 45 mins, and likely more than once as I would never buy after just one look. As far as possible, test cars on your list (including from different makes) on the same 'representative' roads so they can be more easily compared.
Besides the firm ride, I also prefer the non-Sport (or range-topping GTi-type) models as they often offer far better value for money with decent specs and often very good handling and acceptable perfomance. I looked at the Golf GT 1.4 (now 1.5) TSi and its SEAT Leon equivalent (FR - better value) as both are quicker than the Mazda (even in 165 form) in everyday driving without the need to thrash the pants of it to make progress. Unfortunately, that Golf (especially in the far rarer 3rd form) doesn't come with climate control as standard for UK spec cars (it does in the Leon, including the 3dr SC).
As such, I couldn't source a cheaper showroom car for the Golf and wasn't prepared to pay for a new one (little in the way of discounts - about £6k more expensive than the equivalent 3 after discounts). The Leon was a good all-rounder and I was tempted, as they were priced (after discounts) similarly to the Mazda, but in the end my work situation changed and I still have some reservations about VAG engineering quality (reliability as I keep my cars a LONG time). Those cars now come on 18in rims too.
Sometimes, if you have the money, you can downspec the wheels and tyres to smaller ones, but only if the brakes haven't been uprated to ones that only fit the OEM wheel size. My Mazda3 (mk1 from 2005) has 15in brakes and thus when one of my alloys needed changing (corroded and the tyre leaked) and my tyres were a year away from needing replacement, I decided to change from 16in alloys to (still OEM type) 15in alloys and tyres all around.
The difference was only £100 and I'd be getting four, not one new alloy wheels (the other old ones would likely go the same way as the mishapen/corroded one soon and thus need repacling anyway) as the 15in OEM alloys were only 60% of the price of the 16in ones, and the tyres were about 20% cheaper. The other good things were a more cushioned ride, the tyres would last longer and they and the (smaller) alloys would be less susceptible to kerbing type damage, with a small (not very noticeable) reduction in handling ability (more than acceptable for a car that already handles very well - and I'd already driven a TS model with the 15in tyres before and that drove fine).
Changing out wheels and tyres on a new car, unless you have money to burn, isn't that sensible, as you'll never make back the money they cost by flogging the OEMs on Ebay etc. You might get 50-60% back on a ordinary car, which is what the 3 is. That likely means it'll cost you (if its actually possible) best part of £500 - £600 overall to do so. Like me, it might be worth doing that (if you can stomach the 18in's ride for a few years) after 3-5 years for the same reasons I did, as the smaller wheels and tyres will be significantly cheaper than just changing the 18in tyres for some more - Mazda's alloys are unfortunately not renowned for their corrosion resistance, at least those of the mk1 an 2, hence why I changed mine.
The last gen cars alloys may be better, so its worth checking if you are considering this at any stage by checking out early examples of the latest Mazda3 (from 2014) to see if their alloys are not corroding or that much. Bear in mind all large alloys coupled with lower profile tyres are far more susceptable to damage than more 'standard' sized ones like Mazda's 205/60 R16 (or my old 205/55 R16s and replacement 195/65 R15)
I think for you, it'll be whether you, on the Mazda3, find the performance of the Sport 165 (which is hard to get hold of - not many sold/on forecourts) that much different than the 120PS version in the SE, SE-L (including Nav variants) and standard Sport Nav - are you prepared to really give it some welly to get the performance out of either, or do you want a more 'comfortable' car (ride wise) that still has a decent amount of poke for overtaking and the occasional spirited driving.
To me, the test drives (for the 3 and any others you may consider) are the key - numbers on paper/a screen often don't mean much. Just don't go over what you can afford (including longer term running/maintenance costs) - unless you have to change your car, then saying no now means (if you save up for a while longer) saying yes to an affordable one you REALLY like later on.
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