Abstract: A method of manufacturing a reinforcement assembly for a truck bed is provided. The method includes roll-forming an aluminum sheet to form a cross-member having a base, a pair of opposing sidewalls extending from the base, and a pair of flanges each extending from one of the sidewalls and substantially parallel with the base. The method includes extruding an aluminum reinforcement member, and attaching the reinforcement member to the cross-member to space the cross-member from a frame rail of the truck.

Abstract: An aluminum pickup bed is assembled from a stamped headboard, a stamped floorpan, and a roll formed front sill. The headboard, a floorpan flange extending downwardly from the floorpan, and a front wall of the front sill form a three piece sandwich structure. Flow drilled screws are installed into the sandwich structure from the headboard side. The front sill includes a closed front flange and an open rear flange, each of which is welded to the floorpan.

Abstract: A support assembly for an assembly comprised of an extruded member that defines a cavity, the member including an opening having a plurality of sides, and a crush tube inserted into the cavity of the member and mechanically retained in the member at or near a desired location by flanging the sides of the opening into an open end of the crush tube.

Abstract: A pick-up truck tailgate is disclosed that is constructed of components made of aluminum alloys. A hinge reinforcement and hinge plate reinforce a lower corner of the tailgate. A transversely extending reinforcement, including a U-shaped body, is provided within the tailgate that reinforces the central portion of the tailgate. An access panel is provided on the inner panel of the tailgate and includes a hem and fasteners that are assembled to the inner panel through holes formed inboard of the hem.

Abstract: A method of manufacturing a reinforcement assembly for a truck bed is provided. The method includes roll-forming an aluminum sheet to form a cross-member having a base, a pair of opposing sidewalls extending from the base, and a pair of flanges each extending from one of the sidewalls and substantially parallel with the base. The method includes extruding an aluminum reinforcement member, and attaching the reinforcement member to the cross-member to space the cross-member from a frame rail of the truck.

Abstract: A cargo bed assembly for a pickup truck includes an aluminum truck bed above a pair of frame rails. A plurality of roll-formed 6000-series aluminum cross-members extend along a width of the truck bed and contact the underside of the truck bed. The cross-members include longitudinal channels. Each cross-member contacts a pair of extruded 6000-series aluminum spacers underneath the cross-member at spaced locations to align with the frame rails. The spacers contact the frame rails and at least partially surround a portion of the outer surface of the cross-members to separate the cross-members from the frame rails.

Abstract: An aluminum pickup bed is assembled from a stamped headboard, a stamped floorpan, and a roll formed front sill. The headboard, a floorpan flange extending downwardly from the floorpan, and a front wall of the front sill form a three piece sandwich structure. Flow drilled screws are installed into the sandwich structure from the headboard side. The front sill includes a closed front flange and an open rear flange, each of which is welded to the floorpan.

Abstract: A pick-up truck tailgate is disclosed that is constructed of components made of aluminum alloys. A hinge reinforcement and hinge plate reinforce a lower corner of the tailgate. A transversely extending reinforcement, including a U-shaped body, is provided within the tailgate that reinforces the central portion of the tailgate. An access panel is provided on the inner panel of the tailgate and includes a hem and fasteners that are assembled to the inner panel through holes formed inboard of the hem.

Abstract: A cargo bed assembly for a pickup truck includes an aluminum truck bed above a pair of frame rails. A plurality of roll-formed 6000-series aluminum cross-members extend along a width of the truck bed and contact the underside of the truck bed. The cross-members include longitudinal channels. Each cross-member contacts a pair of extruded 6000-series aluminum spacers underneath the cross-member at spaced locations to align with the frame rails. The spacers contact the frame rails and at least partially surround a portion of the outer surface of the cross-members to separate the cross-members from the frame rails.

Abstract: A support assembly for an assembly comprised of an extruded member that defines a cavity, the member including an opening having a plurality of sides, and a crush tube inserted into the cavity of the member and mechanically retained in the member at or near a desired location by flanging the sides of the opening into an open end of the crush tube.

Abstract: A cargo bed assembly for a pickup truck includes an aluminum truck bed above a pair of frame rails. A plurality of roll-formed 6000-series aluminum cross-members extend along a width of the truck bed and contact the underside of the truck bed. The cross-members include longitudinal channels. Each cross-member contacts a pair of extruded 6000-series aluminum spacers underneath the cross-member at spaced locations to align with the frame rails. The spacers contact the frame rails and at least partially surround a portion of the outer surface of the cross-members to separate the cross-members from the frame rails.

Abstract: A vehicle roof support assembly is provided which includes a roof rail, a rocker panel, a first hollow support member and a second hollow support member. The first hollow support member and the second hollow support member each includes an inner wall, an outer wall, a front wall, a front wall and a rear wall. The first hollow support member and the second hollow support member each include a tubular lower area that extends upwardly from the rocker panel. The first hollow support member and the second hollow support member also each include an upper section that extends downwardly from the roof rail. The first hollow support member and the second hollow support member are spaced apart from one another in at least a middle area of the first and second hollow support members.