Abstract: A reinforced structural member is provided which includes a reinforcing member received in the cavity of a structural member. The reinforcing member includes a carrier having divergent, intersecting legs which preferably engage and rest upon the structural member, a thermally expandable reinforcing material, and a fastener for coupling the reinforcing material to the carrier. The thermally expandable reinforcing material is preferably provided as separate elements positioned on the carrier, whereby upon activation by heat, the expandable material melts, foams and expands so that after curing, the structural member is bonded to the carrier. The shape of the carrier in combination with the expanded reinforcing material serves to stiffen and reinforce the structural member. The thermally expandable material is preferably initially dry and non-tacky, and the fasteners serves to maintain the relative position of the reinforcing material elements on the carrier prior to activation of the reinforcing material.

Abstract: An automotive vehicle frame reinforcement system has a skeleton member designed to be secured to a vehicle frame, such as a roof or pillar section. An expandable material, such as an epoxy-based reinforcing foam, is disposed on the skeleton member. Once the system is attached to the frame, the foam expands and cures during an automobile assembly operation, bonding the reinforcement system to the frame. As a result, the reinforcement system provides enhanced load distribution over the vehicle frame without adding excessive weight.

Abstract: The present invention relates to a race care design having a number of novel features. The car is constructed as a tube-frame chassis covered in a stressed steel skin welded thereto, such that the skin becomes a stressed component of the entire car. The car's driveline is assembled using an off-the-shelf transmission and a rear end with custom adaptors to couple the rear end to the transmission and to couple the driveline to the car chassis for rigidity. The prior art rear end is modified from its standard solid rear axle configuration to an independent suspension for each rear wheel through the use of several adaptor components.

Abstract: A frame structure of a body for a motor vehicle and a method of making same. The frame structure includes at least one lateral support arrangement which extends in a longitudinal direction of the motor vehicle between a forward body region and a rearward body region. The at least one lateral support arrangement is arranged to arch over a vehicle occupant compartment above a belt line and is bounded by a roof of the motor vehicle. The at least one lateral support arrangement includes a tube support which is operatively connected with a first reinforcement in a forward body region of the motor vehicle and a second reinforcement in a rearward body region of the motor vehicle. The tube support forms a stiff frame composite for the at least one support arrangement by way of a holding device operatively arranged with the tube supports. The frame structure of the present invention is relatively simple to manufacture and provides optimal stiffness.

Abstract: The invention relates to a motor vehicle convertible roof structure with a folding roof which is movably guided in guide rails (23) in the area of the side members (11) on each side of the vehicle roof. The side members (11) have an extruded section (12) which bears the respective guide rail (23) on its inner side, an outer skin panel section (13) on its outer side and a door and/or window pane seal (14) on its bottom.

Abstract: A straddle type four-wheeled all-terrain vehicle includes: a body frame having a front end part; a front guard joined to the front end part of the body frame; and a winch unit including an electric winch and a guide roller mechanism for guiding a tow rope. The electric winch and the guide roller mechanism are arranged longitudinally from a rear toward a front in that order in a lower part of a space in the front guard.

Abstract: A hollow structural member is reinforced by a housing in the form of a framework exposed structural foam on the housing. The housing is placed in the structural member at an orientation with its longitudinal axis perpendicular to the longitudinal axis of the structural member so that the foam is disposed directly against opposed walls of the structural member. Upon curing the foam becomes intimately bonded to the opposed walls of the structural member and to the housing for reinforcing the structural member. Preferably the housing is formed by extrusion so that it can be cut to size across its extrusion axis.

Abstract: A laminate for reinforcing a structural member having a plurality of side walls comprises a carrier having at least one inclined support surface. Each support surface has an outer edge disposed toward a respective side wall. A layer of extruded uncured structural foam is on each support surface and terminates inwardly of the outer edge. The foam expands when cured and tumbles down the inclined support surface of the carrier to become bonded to the side wall as well as the carrier. By being spaced from the outer edge of the support surface, the tendency for the foam to wipe against the side wall is minimized as is the tendency for a worker to touch the foam when the worker places the carrier into the structural member.

Abstract: A closed channel structural member, such as a side rail or a cross member, for use in a vehicle body and frame assembly, includes an internal reinforcing structure to increase the strength and rigidity thereof. Portions of the side rail are removed so as to provide an opening. This can be accomplished by forming two flanges that can be bent inwardly within the side rail to form the opening. A combined internal reinforcing member and mounting bracket is assembled to the side rail by moving it laterally such that a pair of side walls and an upper wall are inserted through the opening formed through the side rail until tabs provided on the side walls and the upper wall of the reinforcement member and mounting bracket abut the outer surface of the side rail. Then, portions of the reinforcing member and bracket are secured to the side rail by welding.

Abstract: A connecting structure for a vehicle for providing strength while achieving a light weight formation for the vehicle body. The connecting structure connects a sub-constituting member to a main constituting member. The main constituting member is formed in an inverse U-shaped section. A reinforcing pin extends along a connecting direction of the sub-constituting member and is provided to penetrate the main constituting member in a vicinity of the sub-constituting member. A connecting member is superposed on the main constituting member, the sub-constituting member, and the reinforcing pin, and is provided at the connecting portion for connecting the main constituting member and sub-constituting member. The connecting member is integrated to the main constituting member, the sub-constituting member and the reinforcing pin respectively by welding. Both end portions of the reinforcing pin are integrated to the main constituting member by welding.

Abstract: The vehicle body of the present invention includes a first body structure formed from a plurality of tube members and a second body structure formed from sheet metal. The plurality of tube members are loosely fastened together so as to form the first body structure. The first body structure is splayed in a predetermined direction, inserted between two sheet metal members of the second body structure and fixedly secured thereto. Since the tube members are not rigidly fastened together, the tube members are free to move relative to one another in a direction lateral to the longitudinal axis of the vehicle, thereby permitting for size variation in the second body structure. The tube members are then securely fastened together. The design of the first and second body structures facilitates a welding process wherein the welds joining the first and second body structures may be staggered and offset to further improve the rigidity and durability of the vehicle body.

Abstract: A body frame structure for a four-wheeled buggy which is constructed by separately preparing the front sub-assembly and the rear sub-assembly and fastening the rear sub-assembly to the front sub-assembly. The front sub-assembly is composed of a pair of sub-assembly parts each of which is formed as an approximate loop shape including a main frame, a front down frame, a lower frame, and a center frame. Rear ends of the main frames are welded to upper ends of the center frames via a cross pipe. Brackets are provided on upper portions of the center frames in such a manner as to extend upwardly therefrom. Upper fastening portions provided at front ends of seat rails constituting part of the rear sub-assembly are fastened to mounting holes formed in the brackets. Stays are provided on lower portions of the center frames, and lower fastening portions provided at front ends of right and left back stays are fastened to the stays.

Abstract: A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the

Abstract: A frame of a cab for an agricultural machine includes a series of uprights (18), which carry its upper end a structure for supporting a roof (16). The frame includes a first series of sectional elements (18), with cross sections equal to one another, which forms the uprights (18). A second series of sectional elements (32), with cross sections equal to one another, forms the roof-supporting structure (16).

Abstract: A personal conveyance is herein disclosed wherein a space frame or roll cage of an integral passenger and engine compartment is fabricated from at least two (2), preferably elliptical, roll bars that are directly or indirectly associated with a floor pan. In each case, at least one (1) roll bar is integral with and supportive of the perimeter of the floor pan and preferable permanently bonded (e.g. welded) thereto. A second, (and possible multiple roll bars), is then arranged inboard of said horizontal roll bar, in a linear array along the length of the vehicle, and at an inclined angle relative to the plane of the floor pan. The horizontal roll bar is affixed to the inclined roll bar at each point of intersection or coincidence thereof, so as to form an essential unitary structure or roll cage sufficient to accommodate both passenger and power plant compartments.

Abstract: The present invention provides a crash rail for a vehicle. The crash rail has a root portion which can be anchored to a part of the vehicle, a tip portion which is spaced apart from the root portion and which is located nearer a potential impact point of the vehicle when the root portion is anchored to the said part of the vehicle and a middle portion which extends from the root portion to the tip portion. The crash rail comprises a wall which defines a groove or a cavity in the crash rail. The groove or the cavity in the crash rail has a cross-sectional area which increases gradually from the tip portion to the root portion. The wall has a thickness which increases gradually from the tip portion to the root portion. The wall is composed of a composite material having fibers set in a resin material. The crash rail can be crushed when the vehicle impacts with another object to thereby absorb energy of the impact.

Abstract: A joint structure is ideally suited for use in the manufacture of assemblies and subassemblies in aluminum structures. More particularly, the alternative joint structures and methods of forming joint structures facilitate the assembly of a vehicle body-in-white. The friction welded joints of this invention provide assemblies in which lineals and sheet, cast, or extruded components are joined together.

Abstract: A frame structure includes tubular elements joined by an efficient tubular joint with internal low mass stiffening members including a central hollow box section. In the more mass efficient embodiments, the box section includes sides forming continuous extensions through the joint of all the sides of the tubular elements and all edges of each side are fixed to the connecting sides at the joint. In less efficient embodiments provided to simplify manufacturing, some of the interior edges may not be fixed to adjacent sides and/or one or more sides may be omitted from the hollow box section. All versions include extensions of at least part of the sides of each tubular element through the joint to provide mass efficient internal strengthening of the joint for use in tubular frames made with hydroformed or other tubular components.

Abstract: A vehicle frame includes a space frame assembly which is mounted to a pair of longitudinal mainframes. The space frame assembly includes a multiple of interconnected supports, which are configured to support a plurality of vehicle components.

Abstract: In a vehicle, a supporting member running lengthwise is located in the area of the lengthwise sill which is fastened to the pillars A, B, and C and which can support itself on an internal supporting block in the event of a side collision.

Abstract: A partition for forming a barrier in a channel has a molded resin-based plate and a plurality of thermally expandable pellets attached to one side of the plate. The partition is secured in place in the channel by mounting brackets. As heat is applied, a blowing agent in the pellets is activated and the pellets expand to many times their original volume. The resultant foam seals the gap between the plate and the surrounding structure and further secures the plate in place. The partition is particularly useful in forming a sound/water/air barrier in an automotive cavity.

Abstract: The invention relates to a rail vehicle body of the type comprising a grid structure, itself comprising longitudinal elements and cross elements interconnected at nodes, and supporting outer and inner coverings. Longitudinal and cross elements are circular section tubes. At at least some of its nodes, the grid structure comprises connections for interconnecting longitudinal and cross tubes of circular section. These connections have longitudinal and cross circular section sleeves which receive longitudinal and cross tubes respectively. Longitudinal tubes pass right through the connections made of longitudinal and cross tubes.

Abstract: A demonstrator for mounting, operating and displaying a multiplicity of automotive vehicle components comprises an open-frame exoskeleton of aluminum tubes. The tubes are in a configuration suggestive of the shape of an automotive vehicle. The demonstrator is light in weight, is easily shipped and is movable by a single person. A central compartment of the exoskeleton resembles a passenger compartment and has doorways similar in height and width to door openings of the vehicle. A front compartment of the demonstrator resembles a vehicle engine compartment, this compartment defining a generally horizontal window free of other structure of the demonstrator. The front compartment includes front wheel-well outlines defined by tube segments welded together. A rear compartment of the demonstrator similarly defines rear wheel-well outlines.

Abstract: A box-shaped beam for a vehicle, exemplarily a front lateral member (2), with a portion (6) oriented in the longitudinal direction of the vehicle. The portion (6) has, at a distance from a front end, stiffener plates (8) glued to opposite sides (9, 10) of the beam. The glue (11) is of a hard and brittle type which allows the plates to be split off after a certain deformation of the beam occurs so that the section with the plates is rendered less stiff.

Abstract: A side rail assembly for a vehicle having a chassis beam and a protective beam that are secured together by interlocking elements. The protective beam is preferably formed of a softer material than the chassis beam. The protective beam has an outboard wall that is spaced from an inboard wall and s-shaped wall sections interconnecting the outboard wall and inboard wall. The cell walls and an upper portion of the upper wall are preferably curved to facilitate preferential deformation in the event of an impact.

Abstract: A frame structure of a body for a motor vehicle and a method of making same. The frame structure includes at least one lateral support arrangement which extends in a longitudinal direction of the motor vehicle between a forward body region and a rearward body region. The at least one lateral support arrangement is arranged to arch over a vehicle occupant compartment above a belt line and is bounded by a roof of the motor vehicle. The at least one lateral support arrangement includes a tube support which is operatively connected with a first reinforcement in a forward body region of the motor vehicle and a second reinforcement in a rearward body region of the motor vehicle. The tube support forms a stiff frame composite for the at least one support arrangement by way of a holding device operatively arranged with the tube supports. The frame structure of the present invention is relatively simple to manufacture and provides optimal stiffness.

Abstract: Reinforcement (30) for reinforcing a vehicle frame structure (10), having a triangular shape in cross section, including one section (20) in parallel to a side frame member (11), and the other section (21) being attached to a lower section of the side frame member (11). The present invention prevents interference with pipes passing in a lateral direction of the vehicle frame (10) and the exhaust system components. Further, the reinforcement (30) of the invention has a large section modulus, thereby effectively reinforcing the vehicle frame (10).

Abstract: An outer panel is made thinner than an inner panel, and a rear face facing a front door is folded so as to form a valley groove hollowed toward the interior of a tube constituted by true outer panel and the inner panel, whereby when a large magnitude of external force is applied to a front face in a rear ward direction, the outer panel is allowed to be deformed more largely than the inner panel to thereby collapse the valley groove, whereby the rearward travel of the rear face can be reduced.

Abstract: A four-wheeled utility vehicle has a drover's and passenger compartment having open front and lateral sides, and an assist grip (32) that can be grasped by a passenger seated in a natural position on a passenger seat (4b). The assist grip (32) includes a core pipe (33) and an elastic coating member (31) coating the core pipe (33). The assist grip (32) is attached detachably to an upper part of an inclined front side part (21b) on the side of the passenger seat (4b) of a front frame member (21) of a cabin frame (5). The assist grip (32) protrudes toward the passenger seat (4b) to enable the passenger seated on the passenger seat (4b) to grasp the assist grip (32) easily.

Abstract: A center pillar includes an upper member 2 and a lower member 3. The upper member 2 is joined by welding to the lower member 3, such that the upper member 2 is positioned inwardly relative to the lower member 3 in a transverse direction of a vehicle body and is inclined rearward relative to the lower member 3 in longitudinal direction of the vehicle body. In addition, an upper end portion of the lower member 3 has an end face that faces transversely outward and inclines downwardly. A reinforcement plate 6 extends to an upper end portion of the upper member and is joined thereat to the upper member for reinforcement of a state in which the lower member 3 is joined to a side sill 5.

Abstract: A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the

Abstract: An intermediate joint is provided which joints two cylindrical members to form a side member used in a vehicle body. The intermediate joint includes a front and a rear connecting portion and an intermediate coupling portion coupling the front and rear connecting portions. The intermediate coupling portion is so formed physically as to have a degree of rigidity greater than those of the front and rear connecting portions. This improves the strength or rigidity of the intermediate joint without increasing the overall weight of the side member.

Abstract: A fluid formed node is provided to connect structure in an automotive vehicle. Another aspect of the present invention includes a method of forming a structural interconnection including the steps of placing a first member, having an internal cavity in a die pressurizing the internal cavity to form a node integral with and protruding from the first member, disposing the node within an aperture of a second member, and coupling the second member to the node.

Abstract: In a vehicle front pillar including inner and outer frame members joined into a substantial tubular shape, a fore portion of the inner frame member is oriented toward the front of the vehicle and has at least one bent portion formed thereon so as to serve as a shock absorbing section. Rear portion of the inner frame member is oriented toward the back of the vehicle and has a reinforcing member of a closed sectional structure attached thereto so as to serve as a high-rigidity section. The reinforcing member may have a circular or rectangular cross-sectional shape.

Abstract: A reinforcing member for a structural component such as a rail or channel of a vehicle is provided which includes a carrier and a thermally expansible structural reinforcing material element which is fastened to the carrier by mechanical fixation or an adhesive. The mechanical fixation may be provided by a flange or other mechanical connection on the carrier or by a fastener such as a push pin extending through aligned holes and openings in the carrier and foamable material. The push pins are preferably of a synthetic resin material which more closely approximates the heat conductivity of the foamable material when the latter is activated by heat, and is sufficiently yieldable to absorb impacts to the foamable material during installation.

Abstract: A space frame for a motor vehicle is provided to illustrate an embodiment of the invention. The space frame includes a pair of upper longitudinal members. Each of the upper longitudinal members has a pillar forming portion and a first portion coupled to the pillar forming portion. The space frame also includes a cross member having a second portion and a pair of leg portions extending from junctures at each end of the second portion. The space frame additionally includes a pair of laterally spaced side rail structures, which are assembled such that the pillar forming portion of each upper longitudinal member is connected to and forms a pillar on a respective side rail structure. The leg portions of the cross member are each connected to a respective side rail structure and extend upwardly therefrom. The second portion of the cross member connects the pair of side rail structures in laterally spaced relation.

Abstract: The plastic moulding and design structure has a load-bearing structure (3), which is wholly or partly surrounded by a polymer material (8) forming the moulding. The load-bearing structure (3) is formed from several interconnected, high strength, continuous fibre-reinforced structural elements (5). Thus, in a simple and inexpensive manner it is possible to produce structures with the most varied shapes such as containers, tanks, vehicle frames, etc.

Abstract: A vehicle frame part in the shape of a hollow profile is disclosed, with a hollow profile made of light metal being expanded by high internal pressure deformation. A sleeve made of a material with a greater ductility than the light metal, especially a steel material, is slid onto the hollow profile. The sleeve is located on the hollow profile in such fashion that a predetermined area of the hollow profile is covered that is to be deformed during subsequent expansion with a high degree of deformation that exceeds the expandability of the light metal. The hollow profile is expanded by expansion by high internal pressure within this predetermined area to a degree beyond the bursting limit, whereupon the sleeve alone is expanded, subjected directly to high internal pressure at the burst point in the final shaped hollow profile, until the final shape of the part is reached in the area that is covered by the sleeve that is held at both ends in a press fit against the hollow profile.

Abstract: An extruded material frame connection structure for a vehicle, which is constituted by a frame assembly and a reinforcing cover. The frame assembly includes a first extruded member and a second extruded member which are assembled in a state where the first and second extruded members intersect each other and which are welded to each other at an assembled portion thereof so as to be integrated with each other. The reinforcing member is formed to have a size so that the reinforcing member covers the assembled portion between the first and second extruded members and extends to cover portions of the first and second extruded members, the reinforcing member being assembled to the frame assembly and welded to each of the first and second extruded members. With the configuration, it is possible to obtain a frame connection structure in which not only a necessary strength can be secured but also thermal distortion can be suppressed.

Abstract: A space frame includes a pair of laterally spaced, longitudinally extending side rail structures and longitudinally spaced pairs of laterally spaced upright structures having joints at their lower ends with the pair of side rail structures. The longitudinal spaced pairs of laterally spaced upright structures extend upwardly from the side rails structures and define a plurality of pairs of pillars, including a pair of forward A pillars, a longitudinally spaced pair of B pillars, and a longitudinally spaced pair of rearward end pillars. A pair of the side roof structures has joints with the pair of A pillars. The pair of side roof structures extends longitudinally rearwardly from the pair of A pillars and have joints with the pair of B pillars and with the pair of rearward end pillars. Longitudinally spaced cross structures have joints with the pair of side rail structures, with the pair of A pillars and with the pair of side roof structures.

Abstract: An integral body and frame arrangement for an automobile has hollow supporting members which are made out of pressed sheet metal parts and are assembled by at least one joining technique to provide a torsion-proof construction. In one arrangement, at least two U frames are positioned one behind the other in a longitudinal direction of the automobile. The base parts of the U frames are in a floor region of the vehicle body and leg parts of the U frames extend from the floor region to an essentially vertical sidewall vehicle column and/or also extend up to the vehicle roof area. In addition, the U frames are joined directly to each other at least in the region of the free ends of the leg parts or are joined by a flat sidewall part which is mounted on at least one portion of the U frames.

Abstract: A three-dimensional laminate beam is formed by inserting a preformed foam core insert within a hydra-formed metal section having curved three-dimensional geometry. A reinforcing polymer is pumped in and around the foam core insert so as to be adjacent the inside wall of the shell. The polymer bonds to the inside wall of the shell upon the polymer being cured.

Abstract: A structure absorbs impact energy in an upper vehicle body portion provided with a vehicle structural member and an interior trim spaced inward from the structural member. The structure includes an energy absorbing member disposed in the interval between the structural member and the interior trim and extending along the structural member. The energy absorbing member may be a hybrid pipe including a core member formed from a metal foil, and sheets of a different material laminated on opposite surfaces of the core member. The hybrid pipe may be twisted about its longitudinal axis, and/or a shape of a cross section of the hybrid pipe may gradually change in a direction of the longitudinal axis.

Abstract: The object of the present invention is to provide a reinforcement structure for a rear pillar of automobiles. In this structure, a reinforcing panel, forming the upper portion of the rear pillar, is integrated with the welded junction between an inside upper quarter panel and a rear lower roof rail, thus forming a closed cavity within the rear pillar while maximizing the structural strength of rear roof rails. This structure thus allows the top edge of the body's rear portion, formed by the rear roof rails, to effectively and stably support a rear hatch and effectively intercepts noise transmitted from tires of wheels into the passenger compartment through the rear pillars during operation of the automobile. The reinforcing panel extends in a space defined between the inside upper quarter panel and a side panel and is integrated with the lower end of the inside upper quarter panel at its lower end. This reinforcing panel is also integrated with the upper end of the side panel at its upper end portion.

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 fluid formed node is provided to connect structure in an automotive vehicle. Another aspect of the present invention includes a method of forming a structural interconnection including the steps of placing a first member, having an internal cavity in a die pressurizing the internal cavity to form a node integral with and protruding from the first member, disposing the node within an aperture of a second member, and coupling the second member to the node.

Abstract: A hollow reinforced structural member has a bulkhead having a layer of thermally expanded resin disposed between opposed side walls. A sleeve is retained within the resin layer and is oriented perpendicular to the longitudinal axis of the reinforce structural member. The sleeve is an alignment with bolt holes in opposite sides of the reinforced structure such that a bolt can be inserted there through. A component can then be bolted to the reinforced structural member at the site of the reinforcement. The invention not only increases the strength of the part, but also reduces vibration and noise transmission.

Abstract: A structure for a vehicle body having an outrigger integrally coupled with a rear end of a side sill, a side end of a rear cross member and a front end of a rear side frame by means of die-cast molding. The structure may also have a support member supporting a rear trailing arm and a side jack up point, wherein the support member and the side jack up point are integrally coupled with the outrigger by means of die-cast molding.

Abstract: A cross member for use in an automobile body is formed of an extruded material and has a first portion and a second portion. The first portion is formed by vertically stacking two closed sectional portions. The second portion extends downward from one of the front and rear walls of the first portion in the form of an apron. The second portion is provided with a cutout portion matching the contour of the floor tunnel. A bottom wall of the first portion is joined to the top of the floor tunnel, and the edge faces of one closed sectional portion of the first portion are joined to the inner sides of the respective side sills.

Abstract: A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the