Patent ID: 8046197

Claim:
A method comprising: designing a first vehicle component and a second vehicle component by: selecting input values for a first radius (r) of a first portion of a first vehicle component, a second radius (R) of a first portion of a second vehicle component, a minimum clearance (C) between the first and second vehicle components at a distal end of a flange portion of the first vehicle component extending from the first portion of the first vehicle component, wherein the distal end is remote from the first portion of the first component, a length (l) for the flange portion, and a gap (G) between the first and second vehicle components; wherein the first and second vehicle components are partially defined by geometric characteristics of a predetermined outer surface; wherein a predetermined curve is coincident with the outer surface; calculating a first angle of the flange portion of the first vehicle component relative to a line perpendicular to the outer surface based on at least some of the selected input values and geometric characteristics; calculating a second angle of a flange portion of the second vehicle component relative to a line perpendicular to the outer surface based on at least some of the selected input values and geometric characteristics; wherein the flange portion of the second vehicle component extends from the first portion of the second vehicle component; wherein the calculated angles are configured to minimize a distance between the first and second vehicle components on the outer surface at which the first portions of the first and second vehicle components are tangent to the outer surface and converge at the respective radii toward the gap (G); manufacturing the first vehicle component such that the flange portion of the first vehicle component is at the first angle determined by said calculating the first angle; and manufacturing the second vehicle component such that the flange portion of the second vehicle component is at the second angle determined by said calculating the second angle.