Abstract: A process of hydroforming tubular suspension and frame components of a vehicle which results in substantial weight reductions while maintaining strength and integrity of the assembly. The process forms a hydroformed tubular trailing arm having a curved configuration to comply with the design requirements of the suspension. The trailing arm has a spring seat base hydroformed therein, an extruded shock mount and bushing mount formed as integral components. A mounting plate is attached to the trailing arm for attaching the vehicle wheel.

Abstract: A process of hydroforming tubular suspension and frame components of a vehicle which results in substantial weight reductions while maintaining strength and integrity of the assembly. The process forms a hydroformed tubular trailing arm having a curved configuration to comply with the design requirements of the suspension. The trailing arm has a spring seat base hydroformed therein, an extruded shock mount and bushing mount formed as integral components. A mounting plate is attached to the trailing arm for attaching the vehicle wheel.

Abstract: A vehicle door intrusion beam having a hollow cross-sectional configuration with less weight, greater flexibility and improved impact resistance. The beam body is formed of a single piece of material by roll forming a tubular blank to the desired cross-sectional configuration. End brackets secured to or integrally formed with the beam body mount the beam to the door assembly while also facilitating absorption of impacts. Corrugations may be added to the end brackets for additional impact absorption. Various hollow cross-sectional configurations are contemplated for the beam body including a single-piece with a closed I-beam configuration.