New Vehicle Construction

Introduction
Vehicle Body Structure
Bumper reinforcements

Front Rails

Engine Cradles

A, B, C and D Posts

Roof Rails

National Fire and Rescue Magazine 1

Extrication Training by: Doug Cincurak
 Vehicle Body Structure
One-piece hydroformed body side
Door hinges secured rings.
by thick through-
bolts located in A-
and B-pillars.
Cast magnesium transverse
beam behind the instrument
panel.

Hydroformed engine cradle
( not shown )
Triple-rolled A-post
design resists roof
collapse.
Shock towers connected solidly
to instrument panel.
Lateral tie bars that connect the front
longitudinal rails were closed to
stiffen the front structure and
improve crashworthiness.
2
 Enhanced Bumper

Bumper
Reinforcement

3
 Crumple Zones

( Courtesy Of Audi )

4
Beam with Crumple Zones

COLLAPSE
ZONES

5
Crumple Zone Design

6
(HSLA) Beam with Crumple Zones

7
Front Rail Construction

Lower Rail

8
Front Rail Construction

Upper Rail

9
Enhanced Strut Tower

Strut Tower

10
Hydroformed Engine Cradle

11
Engine Cradle Drops

12
A – Post Construction

A-post

13
A – Post Construction

Windshield Post

14
A – Post Construction

Hydroformed

15
B – Post Construction

B-Post

16
 Can your cutter cut this B-Post

How many
layers of
steel do you
see in this
B-Post?

17
A & B Post Reinforcements

18
Construction and Materials

C-Post

19
Construction and Materials

D-Post

20
Construction and Materials

Roof
Reinforcement

21
Roof System Construction

ULTRA
HIGH - STRENGTH
STEEL

22