Abstract: A sliding door for vehicles including a space frame formed from a U-shaped extruded aluminum tube and a crossbeam to which inner and outer aluminum door panels are attached. Hardware for operation of the door is mounted on the exposed inside surface of the door. The overall weight of the door is about 20 pounds and the door is about 35 mm thick. A movable window assembly for such a door and a method of making are also disclosed.

Abstract: A tool for making simultaneously a plurality of parallel friction stir welds includes at least one shank for holding in a chuck or collet of a friction stir welding machine, a plurality of friction stir welding pins, and friction stir welding shoulders including at least four working surfaces adjacent said pins, the shoulders and pins mounted in axial relationship; dimensions of said friction stir welding pins and shanks corresponding to dimensions and spacings of said friction stir welds.

Abstract: A lower control arm for a motor vehicle suspension includes a first member in the form of an elongated hollow member and a second member attached to the first member. The second member has a solid cross section. The second member has a first end attached to the first member and a second end configured for connection to the motor vehicle body. The first member may have at least one opening extending transversely therethrough for connecting the first member to the motor vehicle suspension system.

Abstract: The modular front end forms the front portion of a motor vehicle. The modular front end includes a bulkhead defining a plurality of integrally formed attachment mounts. A drive train assembly carrying at least an engine of the motor vehicle is attached to the bulkhead at the attachment mounts. A crash energy absorption assembly is attached to the attachment mounts on the bulkhead and generally extends around the drive train assembly. An apron assembly is attached to the bulkhead at the attachment mounts and is generally positioned above the drive train assembly and crash energy absorption assembly.

Abstract: The modular front end forms the front portion of a motor vehicle. The modular front end includes a bulkhead defining a plurality of integrally formed attachment mounts. A drive train assembly carrying at least an engine of the motor vehicle is attached to the bulkhead at the attachment mounts. A crash energy absorption assembly is attached to the attachment mounts on the bulkhead and generally extends around the drive train assembly. An apron assembly is attached to the bulkhead at the attachment mounts and is generally positioned above the drive train assembly and crash energy absorption assembly.

Abstract: The liftgate for a motor vehicle includes a frame member, an inner panel, and an outer panel. The frame member is a U-shaped member formed by a cross member and a pair of spaced apart legs extending from the cross member. The inner panel is connected to the legs and extends part way up the legs of the frame member. The outer panel is connected to the inner panel and is positioned opposite the legs and an inner side of the inner panel. The outer panel also extends part way up the legs of the frame member. The frame member defines a window opening with the inner panel and the outer panel. The frame member forms the entire upper portion of the liftgate.

Abstract: An energy absorbing assembly for a vehicle including an elongated crash box having ends with circular cross sections. One end of the crash box is received in a bumper beam and is friction welded to an inside surface of the beam. The other end of the crash box is friction welded to a bracket assembly.

Abstract: A vehicle tailgate extension apparatus and method of using the same. The tailgate extension apparatus generally includes a U-frame member, a plurality of hinge elements, and a plurality of side braces. The U-frame member may be locked into a plurality of operative positions optionally including a backstop position, an extension position, and a step position. The extension apparatus is stored within the interior of the tailgate until needed, and the extension may be pulled out of the tailgate via a plurality of storage channels. The side braces directly connect the U-frame member to the vehicle tailgate and may be stored within the arms of the U-frame when the extension apparatus is stowed in the tailgate.

Abstract: A sliding door for vehicles including a space frame formed from a U-shaped extruded aluminum tube and a crossbeam to which inner and outer aluminum door panels are attached. An elongated hardware carrier beam defines a channel configured to receive vehicle door hardware mounted on the exposed inside surface of the door. The overall weight of the door is about 20 pounds and the door is up to about 35 mm thick.

Abstract: The modular front end forms the front portion of a motor vehicle. The modular front end includes a bulkhead defining a plurality of integrally formed attachment mounts. A drive train assembly carrying at least an engine of the motor vehicle is attached to the bulkhead at the attachment mounts. A crash energy absorption assembly is attached to the attachment mounts on the bulkhead and generally extends around the drive train assembly. An apron assembly is attached to the bulkhead at the attachment mounts and is generally positioned above the drive train assembly and crash energy absorption assembly.

Abstract: The modular front end forms the front portion of a motor vehicle. The modular front end includes a bulkhead defining a plurality of integrally formed attachment mounts. A drive train assembly carrying at least an engine of the motor vehicle is attached to the bulkhead at the attachment mounts. A crash energy absorption assembly is attached to the attachment mounts on the bulkhead and generally extends around the drive train assembly. An apron assembly is attached to the bulkhead at the attachment mounts and is generally positioned above the drive train assembly and crash energy absorption assembly.

Abstract: The liftgate for a motor vehicle includes a frame member, an inner panel, and an outer panel. The frame member is a U-shaped member formed by a cross member and a pair of spaced apart legs extending from the cross member. The inner panel is connected to the legs and extends part way up the legs of the frame member. The outer panel is connected to the inner panel and is positioned opposite the legs and an inner side of the inner panel. The outer panel also extends part way up the legs of the frame member. The frame member defines a window opening with the inner panel and the outer panel. The frame member forms the entire upper portion of the liftgate.

Abstract: A vehicle trailer hitch including an aluminum tubular U-shaped strut and a cast aluminum receiver mounted thereto. Ends of the strut tube are flatted to form integral planar mounting flanges for mounting the hitch to a vehicle.

Abstract: A vehicle tailgate extension apparatus and method of using the same. The tailgate extension apparatus generally comprises a U-frame member, a plurality of hinge elements, and a plurality of side braces. The U-frame member may be locked into a plurality of operative positions optionally including a backstop position, an extension position, and a step position. The extension apparatus is stored within the interior of the tailgate until needed, and the extension may be pulled out of the tailgate via a plurality of storage channels. The side braces directly connect the U-frame member to the vehicle tailgate and may be stored within the arms of the U-frame when the extension apparatus is stowed in the tailgate.

Abstract: The modular front end forms the front portion of a motor vehicle. The modular front end includes a bulkhead defining a plurality of integrally formed attachment mounts. A drive train assembly carrying at least an engine of the motor vehicle is attached to the bulkhead at the attachment mounts. A crash energy absorption assembly is attached to the attachment mounts on the bulkhead and generally extends around the drive train assembly. An apron assembly is attached to the bulkhead at the attachment mounts and is generally positioned above the drive train assembly and crash energy absorption assembly.

Abstract: An energy absorbing assembly for a vehicle including an elongated crash box having ends with circular cross sections. One end of the crash box is received in a bumper beam and is friction welded to an inside surface of the beam. The other end of the crash box is friction welded to a bracket assembly.

Abstract: The modular front end forms the front portion of a motor vehicle. The modular front end includes a bulkhead defining a plurality of integrally formed attachment mounts. A drive train assembly carrying at least an engine of the motor vehicle is attached to the bulkhead at the attachment mounts. A crash energy absorption assembly is attached to the attachment mounts on the bulkhead and generally extends around the drive train assembly. An apron assembly is attached to the bulkhead at the attachment mounts and is generally positioned above the drive train assembly and crash energy absorption assembly.

Abstract: The modular front end forms the front portion of a motor vehicle. The modular front end includes a bulkhead defining a plurality of integrally formed attachment mounts. A drive train assembly carrying at least an engine of the motor vehicle is attached to the bulkhead at the attachment mounts. A crash energy absorption assembly is attached to the attachment mounts on the bulkhead and generally extends around the drive train assembly. An apron assembly is attached to the bulkhead at the attachment mounts and is generally positioned above the drive train assembly and crash energy absorption assembly.

Abstract: A lower control arm for a motor vehicle suspension includes a first member in the form of an elongated hollow member and a second member attached to the first member. The second member has a solid cross section. The second member has a first end attached to the first member and a second end configured for connection to the motor vehicle body. The first member may have at least one opening extending transversely therethrough for connecting the first member to the motor vehicle suspension system.

Abstract: An energy absorbing assembly for a vehicle including an elongated crash box having ends with circular cross-sections. One end of the crash box is received in a bumper beam and is friction welded to an inside surface of the beam. The other end of the crash box is friction welded to a bracket assembly.