Abstract: A method of manufacturing a blow-molded hinge assembly includes blow-molding a first member having a first body. The first body is made from two layers of plastic parison that are molded to form a generally solid plastic T-shaped tongue portion having barrel protrusions. A second member having a second body is also blow-molded. The second body has a recessed portion integrally formed therein. The recessed portion has opposed keyways receiving the barrel protrusions. The recessed portion has slots receiving the T-shaped tongue portion. The second member is formed by blow-molding the recessed portion around a T-shaped slide. The slide has a rounded portion that forms the keyways and a flat portion that forms the slots. After blow-molding the second member, the slide is removed from the recessed portion.

Abstract: A vehicle tailgate assembly having a transverse beam placed between the inner and outer surfaces of a tailgate. The transverse beam transfers a load placed on the tailgate to side plates secured to the transverse beam. The side plates transfer the load to cables that are attached between the side plates and the pickup sides. The transverse beam is generally positioned at the top of the tailgate. Box-like sections were added to the lower portion of the tailgate aligned between the pivot hinges. The box-like sections are formed into the tailgate by joining the inner and outer walls of the tailgate.