Abstract: A one-piece blow molded bumper beam is provided including a series of crush initiators strategically located to inhibit initial outward deflection of the bumper beam upon impact and a pair of grooves for containing a U-bolt type retention device.

Abstract: A motor vehicle bumper system including a closed cross section impact beam having at least one open end and a reinforcing insert in the open end. The reinforcing insert has a central flat wall and a pair of flat, flexible wings attached to the central wall which cooperate with the latter in achieving energy absorbing performance similar to the more complex impact beam inserts having molded, egg crate-type constructions. The flat flexible wings and the central flat wall afford simple press-in installation and frictional retention in the open end of the impact beam.

Abstract: An impact beam includes front, rear, top and bottom side walls connected to form a closed cross section. A foam gusset is formed in place and secured inside the impact beam, preferably along the midpoint of the impact beam. The gusset spans the distance between the front and rear walls, as well as the distance between the side walls to provide increased resistance to deformation.

Abstract: A vehicle hopper construction having longitudinally spaced hopper end slope sheets and hopper cross ridge slope sheets formed prior to assembly in the vehicle hopper so as to provide integral interior hopper corner plates with associated transversely spaced hopper side sheets.