Motor vehicle end module assembly

A method for making a plurality of end module assemblies for installation on ends of a plurality of partially completed vehicles having varying heights and/or widths at their respective ends, said method comprising:

• providing a plurality of exterior fascias that are each configured to comprise a portion of a corresponding vehicle body assembly when said end module assemblies are installed on their corresponding partially completed vehicles;
• providing a plurality of exterior visible components;
• forming a plurality of internal support structures each having a height and width suitable to support said exterior visible components in proper alignment with respect to corresponding ones of said exterior fascias when said exterior visible components are mounted thereto, said internal support structures being formed by a method comprising:
• forming a size determining component for each of said plurality of internal support structures so as to provide said size determining components with varying lengths in a given direction, the length of each of said size determining components in the given direction being determinative of the heights or widths of said internal support structures when said internal support structures are assembled;
• shaping said size determining components by successively feeding blank size determining components of metal material into a die assembly and operating said die assembly to impart the same general shape to each blank size determining component irrespective of the length of said blank size determining components;
• forming remaining components for each of said plurality of internal support structures;
• and
• assembling the size determining component of each internal support structure with the remaining components of each internal support structure so as to form the aforesaid plurality of internal support structures;
• mounting said exterior fascias in place with respect to corresponding ones of said internal support structures, and
• mounting said exterior visible components to corresponding ones of said internal support structures in proper alignment with respect to the corresponding ones of said exterior fascias.