Abstract: A structural composite door for an off-road vehicle includes multiple composite panels such as sheet molding compound (SMC) panels. The panels can define a column proximal to a rearward edge of the door. A door hinge can be connected to the door through screws extending through bushings extending through the column. The door hinge can include shearable stop screws configured to contact a stopping flange when the door is fully opened. A door check can be provided in a space defined by an arm of the door hinge. The door can include a fixed window and a movable window, separated by a divider bar composed of two pieces joined to one another. The door can include a door seal including an upper segment including wipers defining a water gutter between a roll-over protection beam and the door at an upper portion of the door where the door is closed.

Abstract: Methods and tools for assembling an article are provided. The method includes providing a mold having a cavity configured as a desired shape, positioning a base within the mold so that a surface of the base material is exposed, applying a coating material, e.g., urethane or polyurethane, to substantially cover both the exposed surface of the base and an inner surface of the cavity, depositing a cushion material into the cavity and sealing the cavity with the exposed surface of the base so that the coating material forms a skin around the cushion material and adheres the cushion material to the base.