Abstract: A method is provided for assembling a vehicle frame from hydro-formed tubular metal components. Each hydro-formed component has a surface feature that is complementary to a surface feature on an adjacent component. The complementary surface features allow the hydro-formed components to be interlocked together. The components are permanently joined by a plurality of welds. A front hoop, a rear hoop and right and left side hoops may be assembled and joined together to form the passenger compartment portion of the vehicle frame.

Abstract: A moon roof frame module is sized to span between the laterally spaced roof side rails of an automotive roof frame structure and is welded to the opposing roof side rails to be integrated into the roof frame structure. As a result, the moon roof assembly serves as a load path member to reinforce the automotive roof structure. The integrated moon roof frame module will receive roll over forces and increase the strength of the roof structure of an automotive vehicle. The moon roof frame module includes a U-shaped roof panel that is welded to the opposing roof side rails and provides a reinforcing cross member located forwardly of the moon roof opening. A second cross member positioned rearwardly of the moon roof opening increases rigidity of the reinforcing moon roof frame module.

Abstract: A moon roof frame module is sized to span between the laterally spaced roof side rails of an automotive roof frame structure and is welded to the opposing roof side rails to be integrated into the roof frame structure. As a result, the moon roof assembly serves as a load path member to reinforce the automotive roof structure. The integrated moon roof frame module will receive roll over forces and increase the strength of the roof structure of an automotive vehicle. The moon roof frame module includes a U-shaped roof panel that is welded to the opposing roof side rails and provides a reinforcing cross member located forwardly of the moon roof opening. A second cross member positioned rearwardly of the moon roof opening increases rigidity of the reinforcing moon roof frame module.

Abstract: An automotive vehicle body includes a generally tubular, hydroformed cowl with integral mounting flanges which are welded to an engine compartment structural member and a cowlside member. The cowl may be hydroformed from several different preforms having both symmetrical and asymmetrical geometric characteristics.

Abstract: One embodiment of the present invention is a seal apparatus (16) for an improved front-end to body-side joint (10) of a vehicle. The seal apparatus (16) includes a ring portion (36), a gate portion (38), and an intermediate portion (40) extending between the ring portion (36) and the gate portion (38). The ring portion (36) is utilized for receiving an open-ended tubular front-end structure (12) of the improved front-end to body-side joint (10). Additionally, the ring portion (36) is utilized for sealing an interface between the front-end structure (12) and a body-side structure (14). Further, the gate portion (38) is sized for insertion into an interior cavity (42) of the front-end structure (12) and for blocking communication through the interior. Also, the ring portion (36) and/or the intermediate portion (40) have a self-locating construction for positioning the seal apparatus (16) in a predetermined location (50) on the front-end structure (12).