Abstract: An apparatus for a vehicle body including a rocker insert is provided. The apparatus includes a vehicle body including a plurality of metallic structure members and a lower portion operable to provide support to a floor surface within a passenger compartment of a vehicle and a rocker insert mounted to an in-vehicle side portion of the lower portion. The rocker insert includes an elongated bar portion including a hollow center portion including internal reinforcing web features. The rocker insert is oriented with respect to the vehicle body such that a longitudinal axis of the elongated bar portion of the rocker insert is parallel to an in-vehicle forward direction of the vehicle body.

Abstract: An apparatus for a vehicle body including a rocker insert is provided. The apparatus includes a vehicle body including a plurality of metallic structure members and a lower portion operable to provide support to a floor surface within a passenger compartment of a vehicle and a rocker insert mounted to an in-vehicle side portion of the lower portion. The rocker insert includes an elongated bar portion including a hollow center portion including internal reinforcing web features. The rocker insert is oriented with respect to the vehicle body such that a longitudinal axis of the elongated bar portion of the rocker insert is parallel to an in-vehicle forward direction of the vehicle body.

Abstract: A method of edge welding a plurality of workpieces particularly useful for minimizing edge deformation and reducing the electrode size, flange size, welding force and current load necessary to produce a given weld, including the steps of forming at least one distending projection along the edge of a first workpiece, securing the projection against a second workpiece and applying a force and current load to the projection so as to fuse a portion of the projection, and a system for performing the method, including a dedicated projection forming fixture, a resistance welding apparatus preferably having specialized electrodes and a controller communicatively coupled to the fixture and apparatus.

Abstract: The invention contemplates a body structure for a vehicle. The body structure includes a roof panel and a side frame. The attachment flange of an outer body side panel includes a roof mounting portion with a dual angle, a glass mounting portion at an angle that matches one of the dual angles, and a transition area where the dual angle of the roof mounting portion tapers to the glass mounting portion with the single angle.