A structural joint for a pickup truck, according to an exemplary aspect of the present disclosure includes, among other things, a C-pillar, a gusset bracket, a cab back bracket, and a box panel. The C-pillar, gusset bracket, cab back bracket, and box panel are directly welded to each other to provide an assembly having a box section.

A pickup truck box assembly includes a pair of longitudinal frame rails, an extruded cross-member, and a truck bed. The cross-member has a uniform longitudinal cross-section assembled perpendicular to the rails and defines a rectilinear profile with a front flange extending from a cross-member upper portion on a front side and a rear flange extending from the upper portion on a rear side. The truck bed is secured on top of the flanges and the cross-member upper portion. The cross-member may include a first end adjacent a first wheel well defined by the truck bed and a second end adjacent a second wheel well defined by the truck bed such that the cross-member spans between the wheel wells. The ends may be spaced from their respective wheel wells a distance selected to provide space for a truck box inner panel.

A body structure for a passenger car has B-pillar reinforcements of which each have an upper attachment section for attachment to the roof area and a lower attachment section for attachment to the floor assembly or to a side sill. The B-pillar reinforcements are formed as integral tubes made of high-strength steel material and, between the lower attachment sections of the tubes and the upper attachment sections thereof, have a curved course having a constant radius of curvature.

A body structure for a passenger car has B-pillar reinforcements of which each have an upper attachment section for attachment to the roof area and a lower attachment section for attachment to the floor assembly or to a side sill. The B-pillar reinforcements are formed as integral tubes made of high-strength steel material and, between the lower attachment sections of the tubes and the upper attachment sections thereof, have a curved course having a constant radius of curvature.

In a method of manufacturing a vehicle body a side structure and a center structure are positioned in place using a fixture or the like, and fixed by welding with maintained accuracy of mounting positions; annular parts along the width of the cabin of the vehicle and other parts are temporarily mounted to be retained without being welded; additional welding is performed on the center structure and the side structure, and the annular parts along the width of the cabin of the vehicle and other parts are positioned in place using a fixture or the like, and are fixed by welding with maintained accuracy of mounting positions; additional welding is performed on the parts; and a roof complex is mounted and fixed by welding with maintained accuracy of mounting positions.

A front vehicle body reinforcing structure may include a dash panel configured to partition an engine room and a passenger room, front side members deployed at both left and right sides in a width direction of a vehicle, formed to extend in a longitudinal direction of the vehicle, and having rear portions coupled to an outer surface of the dash panel, and a dash upper reinforcing member overlapped with an inner surface of the dash panel to be coupled together with the front side member.

A front vehicle body reinforcing structure may include a dash panel configured to partition an engine room and a passenger room, front side members deployed at both left and right sides in a width direction of a vehicle, formed to extend in a longitudinal direction of the vehicle, and having rear portions coupled to an outer surface of the dash panel, and a dash upper reinforcing member overlapped with an inner surface of the dash panel to be coupled together with the front side member.

A system and method for mounting one or more accessories to a vehicle with forks is disclosed. The system can include a frame comprising mounting plates, the mounting plates including at least an axle hole and a fork stop hole. The frame can also include frame rails to connect the mounting plate to an accessory mount. The system can be mounted to the forks of the vehicle using the axle hole and an axle. A fork stop can be placed in the fork stop hole and can include one or more interface points to fit the bottom of the forks. The fork stop can transmit forces from the accessory to the forks in a linear manner and to a location where the forks have additional strength. The fork stop can be designed such that it bends in response to an impact rather than breaking the forks.

A system and method for mounting one or more accessories to a vehicle with forks is disclosed. The system can include a frame comprising mounting plates, the mounting plates including at least an axle hole and a fork stop hole. The frame can also include frame rails to connect the mounting plate to an accessory mount. The system can be mounted to the forks of the vehicle using the axle hole and an axle. A fork stop can be placed in the fork stop hole and can include one or more interface points to fit the bottom of the forks. The fork stop can transmit forces from the accessory to the forks in a linear manner and to a location where the forks have additional strength. The fork stop can be designed such that it bends in response to an impact rather than breaking the forks.

A passenger compartment of the modular vehicle, such as a bus, includes a roof panel and sandwich-type side panels coupled to structural joiners to form the passenger compartment. The side panels and the joiners may include pultruded beams for increased structural integrity. A chassis of the vehicle has channels integrated therein for coupling of the side panels and passenger compartment to the chassis. This coupling to the chassis channel may also include the use of a bonding agent.