A vehicle front end load bearing bolster is provided with improved structuralperformance and alower component weight, while also minimizing material, tooling, andproduction costs. Thefront end assembly is formed with a hydro-formed cross car reinforcement tubesecured orbonded with mechanical fasteners and room temperature adhesive to a bolster,therebyimproving stress distribution and increasing cross car system stiffness. Thebonded hydro-formtube/bolster assembly provides increased torsion stiffness and dimensionalstability to the vehicleframe. The hydro-formed cross car reinforcement tube have flattened terminalends withapertures for integrated attachment to a bolster. The hydro-formed cross carreinforcement tubeis formed of aluminum, brass, carbon, steel, stainless steel, copper and highstrength alloys. Thebolster is formed of high strength plastics and composites including sheetmolding compounds(SMC), bulk molding compounds (BMC), and thermoplastic compounds such as glassmatthermoplastic (GMT) and direct long fiber thermoplastic (DLFT).
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