An assembly for a vehicle includes a first member including a plurality of elastically deformable locating protrusions extending outward, and a second member defining a cavity extending inward and including a plurality of elastically deformable compression features disposed within the cavity. The locating protrusions of the first member are disposed within the cavity of the second member in press fit engagement with the compression features of the second member to secure the first member relative to the second member. The average of the elastic deformation between all of the locating protrusions of the first member and all of the compression features of the second member precisely aligns the first member relative to the second member. The assembly may include but is not limited to a multiple unit battery pack, a multiple unit fuel cell pack, a dashboard assembly or adjoining body panels.

An embodiment of the present invention relates to a method of manufacturing a vehicle body. The method includes coupling a frame assembly to a platform, wherein the platform is in a cambered and unloaded condition, and wherein the frame assembly has a degree of play at coupling points with the platform and securing the coupling points to eliminate the degree of play and thereby to provide substantially zero residual stress in the vehicle body in the cambered condition.

A large scale composite structure is fabricated by forming a plurality of composite laminate modules and joining the modules together along their edges using scarf joints.

A method and apparatus are provided for extending the length of a vehicle without the need to rebalance the original drive assembly. The method includes disconnecting the front drive shaft segment from the vehicle transmission, extending the length of the vehicle frame, and inserting a drive shaft extension segment which includes: a rigid tubular shaft rotatable about a longitudinal axis; a universal joint mounted at the tubular shaft front end and having a front flange configured for mounting to the transmission; and a bearing assembly mounted to the tubular shaft The extension segment rear end includes a rearward facing flange configured for mounting to a forward facing flange of the front drive shaft segment that was disconnected from the vehicle transmission. The extension segment is installed in the vehicle between the vehicle transmission and the front drive shaft segment without the need to rebalance the original drive assembly.

An airfoil includes a first airfoil piece and a second airfoil piece that is bonded to the first airfoil piece at a joint. The first airfoil piece and the second airfoil piece are formed of aluminum alloys. At least one of the aluminum alloys is an aluminum alloy composition that has greater than 0.8% by weight of zinc. The joint includes a braze element of magnesium, zinc, or combinations thereof in a higher concentration than in other portions of the first airfoil piece and the second airfoil piece.

A mobile fixture configured to move a structure in a manufacturing environment may include a motorized base configured to move on a surface and a support system connected to the motorized base, the support system being configured to support the structure, the support system being configured to position the structure along at least one of an X-axis, a Y-axis, and a Z-axis, the support system being configured to position the structure about the Z-axis, and the support system being configured to provide free rotation of the structure about at least one of the X-axis and the Y-axis.

A method for reinforcing, baffling or sealing a vehicle structure, comprising the steps of providing one or more materials having a horizontal axis, at least one terminating edge, and an initial length, forming openings in the one or more materials, and applying the one or more materials to a location requiring reinforcement, baffling, sealing or any combination thereof.

In a method for producing a multilayered heat shield, which has a first metal layer and a second metal layer that has an insulating layer arranged between the metal layers, the metal layers are connected at the edge by a flanging. To produce the heat shield, the first metal layer, the insulating layer and the second metal layer are placed into a first pressing tool. This is effected in such a way that an edge portion of the first metal layer protrudes beyond an edge portion of the second metal layer. The insulating layer is set back from the edge portions of the first metal layer and of the second metal layer.

A method for reinforcing, baffling or sealing a vehicle structure, comprising the steps of providing a material having openings formed within the material so that the material may be stretched to fit a particular vehicle structure.

A recreational off-highway vehicle includes side-by-side passenger and driver seats held within a chassis that is approximately 50 inches wide. The seats sit low in the chassis and are covered by a roll cage. Grab handles are positioned on the sides of the passenger seat. Select large round tubing protects the vehicle, while rectangular tubing frames the portions of the vehicle beneath body panels. The vehicle is powered by an engine rearward of the seats that is connected to a transaxle. The engine and transaxle are isolation mounted together with a portion of the air intake assembly. The vehicle is suited for rough terrain travel.