Abstract: An extruded rail assembly including a first multi-channel extrusion having at least two tubular channels connected by a center rib, and having a joining end configured for joining at a predetermined angle to a joining end of a second multi-channel extrusion. The second multi-channel extrusion includes at least two tubular channels connected by a center rib, and having a joining end configured for joining at the predetermined angle to the joining end of first multi-channel extrusion. The joining ends of the first and second multi-channel extrusions are configured such that the center ribs complementarily engage as a joining surface.

Abstract: An automotive vehicle includes a vehicle body with a longitudinal axis. The vehicle also includes a rocker inner panel with a first channel having interior and exterior sides. The interior side is secured to the vehicle body. The first channel has a first upper horizontal sidewall, a first lower horizontal sidewall, and a first vertical endwall coupling the first upper and first lower horizontal sidewalls at the interior side. A rocker outer panel is secured to the rocker inner panel. The rocker outer panel includes a second channel, a third channel, and a fourth channel. The second channel is secured to the third channel, and the third channel is secured to the fourth channel. An upper cavity is defined between the second and third channels, an intermediate cavity is defined between the third and fourth channels, and a lower cavity is defined between the second and third channels.

Abstract: An automotive vehicle includes a vehicle body with a longitudinal axis. The vehicle also includes a rocker inner panel with a first channel having interior and exterior sides. The interior side is secured to the vehicle body. The first channel has a first upper horizontal sidewall, a first lower horizontal sidewall, and a first vertical endwall coupling the first upper and first lower horizontal sidewalls at the interior side. A rocker outer panel is secured to the rocker inner panel. The rocker outer panel includes a second channel, a third channel, and a fourth channel. The second channel is secured to the third channel, and the third channel is secured to the fourth channel. An upper cavity is defined between the second and third channels, an intermediate cavity is defined between the third and fourth channels, and a lower cavity is defined between the second and third channels.

Abstract: An extruded rail assembly including a first multi-channel extrusion having at least two tubular channels connected by a center rib, and having a joining end configured for joining at a predetermined angle to a joining end of a second multi-channel extrusion. The second multi-channel extrusion includes at least two tubular channels connected by a center rib, and having a joining end configured for joining at the predetermined angle to the joining end of first multi-channel extrusion. The joining ends of the first and second multi-channel extrusions are configured such that the center ribs complementarily engage as a joining surface.