Various disclosed embodiments include structures and methods for improving assembly of vehicle doors. In an illustrative embodiment a vehicle door includes a first door inner structure having an angled wedge bearing surface and configured to receive a first removable attachment mechanism and a second door inner structure configured to receive a second removable attachment mechanism. The door includes a door outer structure having an outer panel coupled to an attachment structure, the attachment structure having an angled wedge bearing surface and having a bearing surface, the bearing surface configured to receive the second removable attachment mechanism, the second bearing surface being configured to abut an inner surface of the second door inner structure. The door includes an adjustment wedge which allows for positioning of the door panel relative to the body side of the vehicle.

The end portion of a first member includes a plate part and a groove. The end portion of a second member includes an edge and two side surfaces. The groove extends around the edge of the second member and the two side surfaces. The groove includes a side surface including an engaging portion. One of the side surfaces of the end portion of the second member includes an engaged portion. A method for manufacturing a swaged structure includes preparing the first member including the plate part and the groove having a wide opening. The method further includes inserting the end portion of the second member into the groove after preparing the first member. The method further includes pressing the plate part in a direction narrowing the opening of the groove to bring the engaging portion into contact with the engaged portion after inserting the second member.

A door structure includes a door panel, a first beam member, a first bracket attached to a rear end portion of the first beam member, a second beam member formed separately from the first beam member, a second bracket attached to a rear end portion of the second beam member and formed separately from the first bracket, and a coupling member, to which the first bracket and the second bracket are fixed to be arranged side by side, and which is attached to the door panel. The coupling member includes an extending portion extending in a vehicle width direction between the first bracket and the second bracket.

A panel assembly for a vehicle made of different materials with different coefficients of thermal expansion according to various exemplary embodiments of the present invention includes: an external panel 10, an internal panel 20 having the circumference bonded to the circumference of the external panel 10, and made of a material having a coefficient of thermal expansion different from a coefficient of thermal expansion of the external panel 10, and at least one deformation absorption panel 30, 40 connected to at least one of the external panel 10 and the internal panel 20 on the circumferences of the external panel 10 and the internal panel 20, and for absorbing an amount of thermal deformation according to a change in temperatures of the external panel 10 and the internal panel 20 when the external panel 10 and the internal panel 20 are thermally deformed.

A vehicle door assembly includes an inner door panel, a pillar panel and a first cushioning pad. The inner door panel has an attachment area, a first edge portion and a second edge portion, with the first edge portion defining hinge attachment locations. The pillar panel is fixedly attached to at least the second edge portion and the attachment area such that the inner door panel and the pillar panel define a hollow B-pillar structure. The pillar panel further includes an offset portion that is spaced apart from a central portion of the attachment area of the inner door panel such that the attachment area and the offset portion define a recessed area therebetween. The first cushioning pad has a main body installed within the recessed area between the offset portion of the pillar panel and the inner door panel.

A vehicle door assembly includes an inner door panel, a pillar panel and a first cushioning pad. The inner door panel has an attachment area, a first edge portion and a second edge portion, with the first edge portion defining hinge attachment locations. The pillar panel is fixedly attached to at least the second edge portion and the attachment area such that the inner door panel and the pillar panel define a hollow B-pillar structure. The pillar panel further includes an offset portion that is spaced apart from a central portion of the attachment area of the inner door panel such that the attachment area and the offset portion define a recessed area therebetween. The first cushioning pad has a main body installed within the recessed area between the offset portion of the pillar panel and the inner door panel.

A side door assembly is provided for an automotive vehicle body having a side opening. The side door assembly includes an upper door half incorporating a unique outer panel coupled to or integrally formed with a structural portion. Soft goods are operably coupled to the structural portion of the upper door half. The side door assembly includes a one-piece casting for hinged connection to the vehicle body. The casting forms a frame. At least one panel insert is selectively connected from the interior of the vehicle outward by a plurality of rotary attachment features to the frame. The frame includes a plurality of reinforcement features to add structure and rigidity, while reducing weight, to the side door assembly.

A vehicle door assembly is disclosed herein. The vehicle door assembly includes a door. A trim panel has a mount that defines an aperture. A clip that includes a base is coupled to the door. A retainer is coupled to the base and is configured to extend through the aperture defined by the mount to an assembled position, the retainer has an upper portion that is coupled to a lower portion at a vertex to form a projection. A retention feature is coupled to the upper portion and has a ramp. A stop is coupled to the ramp and extends generally downward therefrom to the upper portion. The stop is configured to engage with a back side of the mount to generally prevent the movement of the retainer out of the aperture when the retainer is in the assembled position.

A convertible vehicle door includes a high visibility off-road frame door including a hinge assembly to hingedly couple to a vehicle body, and an exterior on-road panel configured to hingedly couple to the hinge assembly outboard of the high visibility off-road frame door. The convertible vehicle door is convertible between an on-road door configuration where the exterior on-road panel is coupled to the high visibility off-road frame door, and an off-road door configuration where the exterior on-road panel is detached from the high visibility off-road frame door.

There are provided a vehicle-body frame member forming an opening portion for entrance at a vehicle side part and a front side door provided so as to open and close the opening portion. The vehicle-body frame member comprises a side sill, the front side door comprises a door panel portion provided with an inner lower portion which overlaps with the side sill in a vehicle wide view and reinforcement portions provided at two side-portions of a peripheral part of the door panel portion which are continuous and include the inner lower portion such that the reinforcement portions overlap with the vehicle-body frame member in a vehicle side view.