A rear curbside door assembly includes a door frame, a door, and a support member. The door frame includes first and second side frame members, an upper frame member and at least one stair. The second side frame member is spaced from the first side frame member and is configured for releasable attachment to a D-pillar of a body of a vehicle. The upper frame member extends between the first and second side frame members. The at least one stair extends between the first and second side frame members and is spaced from the upper frame member. The door is pivotally coupled with the door frame. The support member is configured for releasable attachment to a body of a vehicle. The support member is releasably attached to the first side frame member. A vehicle including a rear curbside door assembly and methods thereof are also provided.

A method for manufacturing a vehicle frame is disclosed. An upper body of the vehicle frame is formed, the upper body configured to be joined with an underbody of the vehicle frame at a first component of the upper body. The underbody of the vehicle frame is formed, the underbody configured to be joined with the upper body at a first component of the underbody. After forming the upper body and the underbody, a point on the upper body is aligned with a desired position for the point, independent of an alignment between the first component of the upper body and the first component of the underbody. After aligning the point on the upper body with the desired position for the point, the first component of the upper body is joined to the first component of the underbody.

The invention is a modular vehicle that is intended for a variety of operations including both military and civilian operations. The vehicle addresses the issue of performing special purpose tasks that the vehicle is asked to do. Such tasks can be accomplished by configuring the vehicle as an ambulance, as a fire-fighting vehicle, as a communications van, as a command and control vehicle, etc. Thus, the vehicle is readily adapted using standardized and customized modules that are readily attached to a standardized platform that includes an appropriate interconnection means.

A method and assembly station (12) for assembling vehicle body doors (22) utilizes sensing of vehicle body hinge members (26) and door hinge members (28) with the door positioned by a robot (16) to provide assembly with reduced labor cost.

A system for producing a vehicle body assembly in a manufacturing facility is provided. The system includes a forming station configured to form a vehicle body member from a metal material; and an assembly station configured to assemble the vehicle body member with at least one additional vehicle body member to form the vehicle body assembly. The forming station and the assembly station are disposed, in the manufacturing facility, at a predetermined distance from each other, and wherein the predetermined distance is in the range of 0-50 feet.

In a preferred embodiment, there is provided a process for forming a reinforced rocker panel assembly, and which includes positioning a reinforcement patch having first and second patch sections in surface-to-surface contact with a blank panel sheet, and welding the first patch section to the blank panel sheet. The process further includes bending both the blank panel sheet and the reinforcement patch along a bend line interposed between the first and second patch sections to form the blank panel sheet into a rocker panel portion having an elongated base section and a longitudinal flange, where the first and second patch sections are in at least partial abutting contact with the base section and the flange. The process also includes welding the second patch section to the flange.

An embodiment structure for a vehicle includes a front-end module carrier, a front side member, a fender apron assembly disposed on an upper portion of the front side member, and connecting members connecting the front-end module carrier and the fender apron assembly. Another embodiment structure for a vehicle includes a front side member, a front-end module carrier, a fender apron assembly disposed on an upper portion of the front side member, the fender apron assembly including a shock absorber housing coupled to the upper portion of the front side member, and connecting members connecting the front-end module carrier and the fender apron assembly, the connecting members including a lower connecting member extending from the front-end module carrier and connecting the shock absorber housing and the front side member.

A hybrid structural assembly includes a vehicle structural member extending from a first end to a second end, and a composite reinforcement member attached to the vehicle structural member between the first and second ends of the vehicle structural member. The composite reinforcement member being formed by a continuous method and cut to a predetermined length extending from the first end to the second end.

An assembly includes a first component having a first threaded opening therein, and a second component having a second component opening therethrough. A bolt assembly secures the second component relative to the first component. The bolt assembly includes a first bolt having a spacer portion and a first threaded shaft extending from the spacer portion to engage the first threaded opening. The first bolt includes an internal thread extending axially from the spacer portion. The bolt assembly further includes a second bolt having a head and a second threaded shaft extending from the head. The second threaded shaft extends through the second component opening to engage the internal thread of the first bolt to secure the second component relative to the first component.

A frame for a personal electric vehicle includes (a) a chassis floorpan extending axially between a front and a rear and laterally between opposite sides, the floorpan having a floor and a sidewall extending upwardly from a periphery of the floor to a raised peripheral edge of the floorpan; and (b) a safety cage mounted to the chassis floorpan and comprising a plurality of interconnected tubular members defining an occupant interior. The tubular members include a plurality of pillars spaced apart from each other along the peripheral edge and fixed against the sidewall for securing the safety cage to the chassis floorpan.