Abstract: Expanded, toughened structural adhesives form stiffening materials for vehicular panels and bodyshell structures. The toughened structural adhesive contains an epoxy resin, a rubber, an elastomeric toughener, a curing agent, and an expanding agent. The expanded structural adhesive greatly increases the amount of energy absorbed by the panel or bodyshell structure during an impact. A blowing agent combination of a chemical blowing agent with expandable microballoons provides for especially good energy absorption.

Abstract: Structure is provided for joining and bonding together two halves of a plastic upper body member which in turn are joined and bonded to a fiber reinforced lower member to comprise a monocoque vehicle assembly. The joint designs facilitate side-to-side and fore-and-aft alignment for quick and easy assembly of the upper body member to the lower member. Spacer surfaces are provided for controlling adhesive reservoirs between adjoining surfaces to facilitate positive bonding.

Abstract: A plastic monocoque body useful with small vehicles, such as lawn and garden tractors. A lower fiberglass reinforced plastic frame member is bonded to two upper body members to form a monocoque body. The assembly incorporates attaching, pivot and support structures for the engine, transaxle and drive wheels, steerable front wheels, steering mechanism, clutch and brake pedals and control linkages, shift and throttle controls and linkages, adjustable mower deck, adjustable seat and battery. Through utilizing the net shape manufacturing process, no metal skeleton is required, thereby reducing the expense and complexity of manufacture, assembly and paint operations.