Abstract: A vehicle door assembly includes an inner door panel, a pillar panel and a first cushioning pad. The inner door panel has an attachment area, a first edge portion and a second edge portion, with the first edge portion defining hinge attachment locations. The pillar panel is fixedly attached to at least the second edge portion and the attachment area such that the inner door panel and the pillar panel define a hollow B-pillar structure. The pillar panel further includes an offset portion that is spaced apart from a central portion of the attachment area of the inner door panel such that the attachment area and the offset portion define a recessed area therebetween. The first cushioning pad has a main body installed within the recessed area between the offset portion of the pillar panel and the inner door panel.

Abstract: A vehicle door assembly includes an inner door panel, a pillar panel and a first cushioning pad. The inner door panel has an attachment area, a first edge portion and a second edge portion, with the first edge portion defining hinge attachment locations. The pillar panel is fixedly attached to at least the second edge portion and the attachment area such that the inner door panel and the pillar panel define a hollow B-pillar structure. The pillar panel further includes an offset portion that is spaced apart from a central portion of the attachment area of the inner door panel such that the attachment area and the offset portion define a recessed area therebetween. The first cushioning pad has a main body installed within the recessed area between the offset portion of the pillar panel and the inner door panel.

Abstract: A vehicle door assembly include an inner door panel, a first hinge and a guard beam. The inner door panel has a first edge portion and a second edge portion. The first edge portion has a first hinge attachment location and a second hinge attachment location with the first hinge location having a first opening and a second opening. The first hinge is dimensioned and configured to attach to the first hinge attachment location of the inner door panel. The guard beam has a first end and a second end. The first end has a first fastener and a second fastener rigidly and non-movably attached thereto. The first fastener is inserted through the first opening and the second fastener extends through the second opening in the first hinge attachment location, the first and second fasteners further fastening to the first hinge thereby attaching the first hinge to the door panel.