Abstract: A method of constructing vehicle frames of varying lengths from a flexible modular architecture is provided. The method comprises: providing substantially identical front and rear modules, and providing middle modules with constant-section longitudinal rails that are formable to a variety of desired lengths. The components are selected by trimming or forming a first middle module to a first longitudinal length and selecting one each of the substantially identical front and rear modules. A first frame, having a first frame length, is then assembled from the formed first middle module and substantially identical front and rear modules. After forming another middle module to a second length; a second frame, having a different frame length, may then be assembled from the second formed middle module and a second pair of substantially identical front and rear modules. An assembly for constructing frames of varying lengths from a flexible modular architecture is also provided.

Abstract: A hollow beam for incorporation in an automotive vehicle frame is useful as a transmission cross member extending between side rails of the automotive vehicle frame. The hollow beam has first and second U-shaped channels, each comprising a base wall and a pair of side walls extending transversely from the base wall. The channel members are made of a thermosetting polyester which is reinforced with glass fibers. The side walls of the second channel are received within the sidewalls of the first channel and adhered thereto with epoxy to form a rigid, relatively light weight beam. The beam has figure-8 shaped aluminum inserts proximate the ends thereof for attaching the beam to the side rails of the automotive vehicle frame.

Abstract: A mount for a rack and pinion steering gear on a body structure of a motor vehicle including a horizontal tubular boss on the steering gear parallel to a longitudinal centerline of the body structure, a tubular sleeve rigidly clamped to the body structure inside of the tubular boss having a pair of rigid flanges at opposite ends thereof, and an elastomeric bushing on the tubular sleeve between the rigid flanges. The elastomeric bushing has a tubular body bonded to the tubular sleeve and a plurality of integral linear splines compressed radially between the tubular sleeve and an inside cylindrical wall of the tubular boss. The linear splines flex resiliently to suppress the transfer of linear vibrations from the steering gear to the body structure.

Abstract: An intermediate shaft seal for installation at an opening in a dash panel of a vehicle remove extra space includes an inner shell, an overmold and a bushing assembly. The bushing assembly includes a pair of bushings and is disposed within the inner shell to rotatably support an intermediate shaft of a steering column of a vehicle. The inner shell includes a rigid base plate and sealing ridges for mounting against a dash panel of a vehicle and providing a seal against water, fumes and dirt intrusion. The overmold engages locking features on the inner shell and forms air gaps therebetween cooperating with the sealing ridges and bushings to establish a sound attenuating structure. The inner shell and the overmold include cooperating sinuous shaped sections allowing angular flexibility of the seal for installation in various model vehicles.