Abstract: A module for a frame for a motor vehicle and a method of forming a frame assembly with a pair of laterally spaced, longitudinally extending central side rail structures includes, in one embodiment, using a pair of tubular hydroformed side rail members and a laterally extending connecting structure connected between the pair of side rail members to secure the pair of side rail members in laterally spaced, fixed relation to one another. Each first portion of the pair of side rail members extending longitudinally and each second portion of the pair of side rail members extending laterally relative to the respective first portion and each second portion having an end being constructed and arranged to form a joint with a portion of a respective central side rail structure such that the end of each of the pair of side rail members extends generally laterally through a side of the respective central side rail structure.

Abstract: A module for a frame for a motor vehicle with a pair of laterally spaced, longitudinally extending central side rail structures. The module including a pair of tubular hydroformed side rail members and a laterally extending connecting structure connected between the pair of side rail members to secure the pair of side rail members in laterally spaced, fixed relation to one another. Each first portion of the pair of side rail members extending longitudinally and each second portion of the pair of side rail members extending laterally relative to the respective first portion and each second portion having an end being constructed and arranged to form a joint with a portion of a respective central side rail structure such that the end of each of the pair of side rail members extends generally laterally through a side of the respective central side rail structure.

Abstract: A space frame for a motor vehicle having a pair of laterally spaced, longitudinally extending side rail structures, a pair of forward-most upright structures each being connected to a respective side rail structure, thereby forming a pair of A pillars, a pair of roof rail structures, a forward end of each roof rail structure being connected to an upper end of an associated A pillar, and a rearward ring assembly connected at upper portions thereof with the roof rail structures and at bottom portions thereof with the side rail structures. The rearward ring assembly having (a) a tubular hydroformed inverted U-shaped upper member having a cross portion and a pair of leg portions extending downwardly from opposite ends of the cross portion, (b) a pair of tubular hydroformed side members, and (c) a cross structure rigidly connected in ring-forming relation between the second ends of the side members.

Abstract: A welding material is constructed and arranged to be positioned in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material includes at least one welding material member constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the exterior surface of the first weldable member and then positioned between the exterior surfaces of the first and second weldable members to be electrically conductively disposed therebetween.

Abstract: A space frame for a motor vehicle having a pair of laterally spaced, longitudinally extending side rail structures, a pair of forward-most upright structures each being connected to a respective side rail structure, thereby forming a pair of A pillars, a pair of roof rail structures, a forward end of each roof rail structure being connected to an upper end of an associated A pillar, and a rearward ring assembly connected at upper portions thereof with the roof rail structures and at bottom portions thereof with the side rail structures. The rearward ring assembly having (a) a tubular hydroformed inverted U-shaped upper member having a cross portion and a pair of leg portions extending downwardly from opposite ends of the cross portion, (b) a pair of tubular hydroformed side members, and (c) a cross structure rigidly connected in ring-forming relation between the second ends of the side members.

Abstract: An apparatus and method for welding members that are formed at least in part of aluminum. A welding assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. A welding method includes alternatively attaching the welding material members to a weldable member without a carrier sheet, by a welding process.

Abstract: A door seal interface structure for a motor vehicle space frame includes a longitudinally extending hydroformed tubular rail portion, a hydroformed tubular pillar portion connected at a joint to the rail portion and a transition structure. The rail portion and the pillar portion provide respective surface portions constructed and arranged to sealingly engage a door seal to seal a peripheral portion of a closed vehicle door. The pillar and rail surface portions are angularly related to one another in the vicinity of the joint. The transition structure is mounted on the rail portion and the pillar portion in the vicinity of the joint and provides a transition surface that provides a transition between the pillar and rail surfaces of the pillar and rail portions, the transition surface portion being constructed and arranged to sealingly engage a portion of the door seal to seal the closed vehicle door and thereby provide a door seal-engagable surface in the vicinity of the joint.

Abstract: A welding material assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the sheet such that when the sheet is placed between the exterior surfaces of the first and second weldable members to be welded, each welding material member is electrically conductively disposed therebetween.

Abstract: An apparatus and method for welding members that are formed at least in part of aluminum. A welding assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. A welding method includes alternatively attaching the welding material members to a weldable member without a carrier sheet, by a welding process.

Abstract: A welding material is constructed and arranged to be positioned in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material includes at least one welding material member constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the exterior surface of the first weldable member and then positioned between the exterior surfaces of the first and second weldable members to be electrically conductively disposed therebetween.

Abstract: A welding material assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the sheet such that when the sheet is placed between the exterior surfaces of the first and second weldable members to be welded, each welding material member is electrically conductively disposed therebetween.

Abstract: A door seal interface structure for a motor vehicle space frame includes a longitudinally extending hydroformed tubular rail portion, a hydroformed tubular pillar portion connected at a joint to the rail portion and a transition structure. The rail portion and the pillar portion provide respective surface portions constructed and arranged to sealingly engage a door seal to seal a peripheral portion of a closed vehicle door. The pillar and rail surface portions are angularly related to one another in the vicinity of the joint. The transition structure is mounted on the rail portion and the pillar portion in the vicinity of the joint and provides a transition surface that provides a transition between the pillar and rail surfaces of the pillar and rail portions, the transition surface portion being constructed and arranged to sealingly engage a portion of the door seal to seal the closed vehicle door and thereby provide a door seal-engagable surface in the vicinity of the joint.