Abstract: A method of coupling a plurality of parts together includes casting a first part to include a base and a protrusion that protrudes from the base. The first part is made from a metallic material. The method also includes providing a second part with an opening and mating the first and second parts such that the protrusion is received within the opening. Moreover, the method includes deforming the protrusion over the second part such that the second part is retained between the deformed protrusion and the base of the first part.

Abstract: A spare tire carrier for a vehicle may structurally entail a base, a mounting flange extending from the base, a vertical support post extending from the base, a light support post attached to the vertical support post, a threaded stud that engages a front surface of the base to support a spare tire. A tether, which may be secured to the base with a fastener, may lie largely concealed within the base and have additional studs or bolts which may protrude through a front surface of the base and further support a spare tire. A plurality of strength ribs may join the mounting flange and the base, while the base, the first mounting flange, vertical support post extending from the base, and plurality of strength ribs may be a single cast magnesium part. The tether may be of another high strength material.

Abstract: A spare tire carrier for a vehicle may structurally entail a base, a mounting flange extending from the base, a vertical support post extending from the base, a light support post attached to the vertical support post, a threaded stud that engages a front surface of the base to support a spare tire. A tether, which may be secured to the base with a fastener, may lie largely concealed within the base and have additional studs or bolts which may protrude through a front surface of the base and further support a spare tire. A plurality of strength ribs may join the mounting flange and the base, while the base, the first mounting flange, vertical support post extending from the base, and plurality of strength ribs may be a single cast magnesium part. The tether may be of another high strength material.

Abstract: A stiff torque box is used with frame rail segments to compose a vehicle frame. The stiff torque box is used to cross-link the left hand and right hand sides of a vehicle frame and is made up of an extruded aluminum skeleton which forms a number of internal cavities, as well as connecting tabs. The connecting tabs are used to fix the frame rail segments to the stiff torque box. Implementing stiff torque boxes in vehicle frame construction allows for more rigid vehicle frames with the advantage of additional weight savings. This construction is ideal for aluminum frame, front wheel drive and body on frame vehicles. Because of the characteristics of such a vehicle frame, opportunities arise to implement other weight conservative vehicle components.

Abstract: An engine block includes a unitary engine block casing having a cylinder wall and an upper peripheral wall spaced from the cylinder wall to define an open channel therebetween. The channel has a bottom formed by a portion of the engine block casing and an open top formed between the cylinder wall and the peripheral wall. An independent insert member is disposed in the open top of the channel extending between the cylinder wall and the peripheral wall for providing structural support between the cylinder wall and the peripheral wall. The invention further includes a method for diecasting the engine block using permanent molds.