Patent ID: 7125067

Claim:
A door assembly for a vehicle comprising: an outer door panel having a first opening to define a window opening in said door assembly above a lower body portion of said outer door panel; a magnesium inner door panel being formed with a peripheral edge and a mounting face, said peripheral edge having a bottom portion, a top portion and opposing side portions defining a second opening in said inner door panel, said second opening being larger than said first opening and overlapping said lower portion of said outer door panel, said inner door panel including corrugated mounting lugs disposed thereon a reinforcement beam connected to said inner door panel adjacent said opposing side portions of said peripheral edge, said reinforcement beam being mounted on said mounting lugs and spanning across said second opening above said bottom portion, said reinforcement beam having a height dimension that is smaller than a corresponding height dimension of said lower body portion of said outer door panel, said reinforcement beam having a corrugated configuration with correspondingly corrugated attachment flanges on opposing ends thereof said corrugated attachment flanges having a corrugated shape corresponding to said mounting lugs to permit attachment of said reinforcement beam directly to said mounting face of said inner door member; and said inner door panel; and modular hardware attachment panel being mounted to said mounting face of said inner door panel to position a portion of said inner door panel between said modular hardware attachment panel and said outer door panel, said modular hardware attachment panel having a width dimension substantially equal to a corresponding width dimension of said outer door panel.