Abstract: A method of manufacturing a vehicle chassis and a vehicle chassis that is formed in modules with couplers for connecting extruded beams. The method includes extruding a plurality of beams and a plurality of couplers that are loosely assembled together to a fixture having locating pins that are received in pockets formed on the couplers and securing the beams and couplers together to form a chassis. The chassis includes a center chassis module to which the fire wall bulkhead and passenger compartment are secured, a drive train and front suspension module to which the engine transmission and front suspension are attached, a rear suspension module to which the rear suspension and gas tank are secured, and front and rear crush modules including the front and rear bumper assemblies, respectively. Couplers used in forming the chassis include a central portion having an outer wall and a plurality of inner walls extending inwardly from the outer wall to the pocket.

Abstract: A method of manufacturing a vehicle chassis and a vehicle chassis that is formed in modules with couplers for connecting extruded beams. The method includes extruding a plurality of beams and a plurality of couplers that are loosely assembled together to a fixture having locating pins that are received in pockets formed on the couplers and securing the beams and couplers together to form a chassis. The chassis includes a center chassis module to which the fire wall bulkhead and passenger compartment are secured, a drive train and front suspension module to which the engine transmission and front suspension are attached, a rear suspension module to which the rear suspension and gas tank are secured, and front and rear crush modules including the front and rear bumper assemblies, respectively. Couplers used in forming the chassis include a central portion having an outer wall and a plurality of inner walls extending inwardly from the outer wall to the pocket.

Abstract: A method of manufacturing a vehicle chassis and a vehicle chassis that is formed in modules with couplers for connecting extruded beams. The method includes extruding a plurality of beams and a plurality of couplers that are loosely assembled together to a fixture having locating pins that are received in pockets formed on the couplers and securing the beams and couplers together to form a chassis. The chassis includes a center chassis module to which the fire wall bulkhead and passenger compartment are secured, a drive train and front suspension module to which the engine transmission and front suspension are attached, a rear suspension module to which the rear suspension and gas tank are secured, and front and rear crush modules including the front and rear bumper assemblies, respectively. Couplers used in forming the chassis include a central portion having an outer wall and a plurality of inner walls extending inwardly from the outer wall to the pocket.

Abstract: A side rail assembly for a vehicle having a chassis beam and a protective beam that are secured together by interlocking elements. The protective beam is preferably formed of a softer material than the chassis beam. The protective beam has an outboard wall that is spaced from an inboard wall and s-shaped wall sections interconnecting the outboard wall and inboard wall. The cell walls and an upper portion of the upper wall are preferably curved to facilitate preferential deformation in the event of an impact.