Abstract: An assembly is provided that includes a front end support frame and radiator support beam. The front end support frame has an end that defines an opening that extends between two facing walls across an inside wall of the tubular structure. The radiator support beam is assembled into the opening in the end of the front end support frame and is attached to the two facing walls. The front end support frame is a hydro-formed tube and the radiator support beam is an extruded part. The radiator support beam includes at least one internal reinforcement wall and an outside wall of the front end support frame is fastened with flow drilling screws to the internal reinforcement wall.

Abstract: An assembly is provided that includes a front end support frame and radiator support beam. The front end support frame has an end that defines an opening that extends between two facing walls across an inside wall of the tubular structure. The radiator support beam is assembled into the opening in the end of the front end support frame and is attached to the two facing walls. The front end support frame is a hydro-formed tube and the radiator support beam is an extruded part. The radiator support beam includes at least one internal reinforcement wall and an outside wall of the front end support frame is fastened with flow drilling screws to the internal reinforcement wall.

Abstract: An assembly is provided that includes a front end support frame and radiator support beam. The front end support frame has an end that defines an opening that extends between two facing walls across an inside wall of the tubular structure. The radiator support beam is assembled into the opening in the end of the front end support frame and is attached to the two facing walls. The front end support frame is a hydro-formed tube and the radiator support beam is an extruded part. The radiator support beam includes at least one internal reinforcement wall and an outside wall of the front end support frame is fastened with flow drilling screws to the internal reinforcement wall.

Abstract: An assembly is provided that includes a front end support frame and radiator support beam. The front end support frame has an end that defines an opening that extends between two facing walls across an inside wall of the tubular structure. The radiator support beam is assembled into the opening in the end of the front end support frame and is attached to the two facing walls. The front end support frame is a hydro-formed tube and the radiator support beam is an extruded part. The radiator support beam includes at least one internal reinforcement wall and an outside wall of the front end support frame is fastened with flow drilling screws to the internal reinforcement wall.

Abstract: A vehicle front end structure includes a hinge pillar having laterally spaced first and second vertical mounting surfaces that extend in a longitudinal direction. The vehicle also includes a tubular support member having a first wall secured to the first vertical mounting surface and a second wall secured to the second vertical mounting surface. The second wall extends rearward of the first wall and is secured to the hinge pillar laterally outboard of the first wall. A notched portion through at least one horizontal wall interconnecting the first and second walls of the tubular support may operate as a buckling location of the tubular support.

Abstract: A body structure for a vehicle includes a cowl side defining a first vertical and longitudinal plane. A hinge pillar including a tab portion is attached to the cowl side in the first plane. The hinge pillar includes a stepped surface defining a second vertical and longitudinal plane that is offset outwardly from the first plane and parallel to the first plane. A front end rail includes an inner sidewall fastened to the cowl side and an outer sidewall fastened to the stepped surface the stepped surface. The longitudinal loads applied to the front end rail are transferred in shear to the hinge pillar and cowl side.