METHOD OF MANUFACTURING DOOR MODULE ASSEMBLY

摘要

A method of manufacturing a multiplicity of door module assemblies for a motor vehicle comprising forming a plurality of outer door panels (12); forming a plurality of inner door panels (14) and a plurality of door hardware mounting panels (16) from sheet metal, wherein i) the inner door panels (12) are each constructed from a portion of sheet metal formed to have a peripheral shape generally matching that of the outer door panels (12) and to define an area which is to constitute a major opening (18) in the inner door panel (14), and ii) each of said door hardware mounting panels (16) are simultaneously stamped with an associated one of said inner door (14) panels from a portion of sheet metal occupying at least a portion of the area which is to constitute the major opening (18) in an associated one of said inner door panels (14); separating the portions of sheet metal forming the door hardware mounting panels (16) from the associated portions of sheet metal forming the inner door panels (14) after the door hardware mounting panels (16) and the inner door panels have been stamped into their respective peripheral shapes; fixing each of the inner door panel (14) to a respective one of the outer door panels (12); mounting door hardware on said door hardware mounting panels (16); and mounting each of the door hardware mounting panels (16) on a respective one of the inner door panels (14) after the door hardware has been mounted on the door hardware mounting panels (16).