Abstract: A hitch assembly for mounting to a frame assembly of a vehicle comprises a one-piece hitch mounting structure having a general U-shape with opposing end portions and a centrally disposed intermediate portion between the end portions. A hitch receiver is mounted to the intermediate portion of the hitch mounting structure. The end portions each include a mounting section with a general L-shaped cross-sectional configuration, thereby providing the end portions with horizontally extending mounting flanges structured to mount the hitch assembly to the frame assembly of the vehicle.

Abstract: A method for making a beam from a metal sheet (10), includes the steps of providing a metal sheet having opposite first and second side edges (12, 14) extending longitudinally along opposing sides of the metal sheet, and a first and a second generally parallel opposing face surfaces (16, 18) provided between the first and second edges. The first and second generally parallel opposing faces define a thickness of the metal sheet therebetween. The thickness of the metal sheet is split at one of the first and second side edges to form first and second integral flanges (28, 30, 32, 34) from a portion of the metal sheet such that inner ends of the first and second flanges remain integrally connected with an unsplit portion (44) of the metal sheet. The first and second flanges are then bent so as to provide the metal sheet with a tubular portion extending along one side of and integrally formed with the unsplit portion. The first and second flanges are then fixed against movement relative to one another.

Abstract: A collapsible driveshaft and method of making the same. The collapsible driveshaft includes a tubular member having first and second portions that are integrally formed as a one-piece member. The first portion has splines formed on an exterior surface thereof. The second, opposite portion has both outer and inner diameters that are greater than the outer diameter of the first portion. The method includes placing a tubular metal blank into a hydroforming die having a die cavity and expanding the blank by pressurizing the interior of the blank with hydroforming fluid. During the hydroforming process, the first portion of the blank is expanded to form splines while the second portion is expanded to form inner and outer diameters that are greater than the outer diameter of the first portion.

Abstract: A vehicle space frame for constructing a motor vehicle includes a body module and a front module. The body module includes a pair of laterally spaced, longitudinally extending main side rail structures and a pair of rearward-most upright structures each being connected to a respective main side rail structure and extending upwardly therefrom to form a pair of rearward-most pillars thereon. The body module further includes a pair of hydroformed upper longitudinal members each being defined by an outwardly deformed tubular metallic wall fixed in a predetermined irregular exterior surface configuration and each including a pillar-forming portion and a longitudinally extending portion.

Abstract: Decorative exterior body panels for use on motor vehicles and methods for making the same are presented. Layers of thermoplastic material are sandwiched to produce a laminate. The laminate is then heated and vacuum formed into a selected body panel shape. To further ease the process of production of the vehicle body, the panel may have integral decorative material. Such a panel does not require paint or other extra steps to provide a finished look to the vehicle body. The top layer of the laminate is transparent, allowing the second layer to be seen. The second layer is a decorative material such as fabric or any colored, textured or reflective material.

Abstract: A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the

Abstract: A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the

Abstract: A space frame for a motor vehicle is provided to illustrate an embodiment of the invention. The space frame includes a pair of upper longitudinal members. Each of the upper longitudinal members has a pillar forming portion and a first portion coupled to the pillar forming portion. The space frame also includes a cross member having a second portion and a pair of leg portions extending from junctures at each end of the second portion. The space frame additionally includes a pair of laterally spaced side rail structures, which are assembled such that the pillar forming portion of each upper longitudinal member is connected to and forms a pillar on a respective side rail structure. The leg portions of the cross member are each connected to a respective side rail structure and extend upwardly therefrom. The second portion of the cross member connects the pair of side rail structures in laterally spaced relation.

Abstract: A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the