Magnesium door assembly for automobiles

A door assembly for a vehicle, comprising an outer door panel having a window opening and a lower body portion below said window opening;

• a magnesium inner door panel being formed with a peripheral edge and a mounting face, said peripheral edge including a bottom portion, a top portion, and opposing side portions defining a second opening in general alignment with said window opening, said inner door panel being attached to said outer door panel by a hem, said inner door panel including a plurality of reinforcing ribs spaced around said peripheral edge;
• a modular hardware attachment panel adapted to receive door hardware, said 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;
• and
• a reinforcement beam connected by fasteners to said inner door panel at said opposing side portions of said peripheral edge and being positioned between said inner door panel and said outer door panel to extending along said inner door panel above said bottom portion of said peripheral edge, 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 inner door panel including corrugated mounting lugs disposed therein adjacent said opposing side portions of said peripheral edge, said mounting lugs having a corrugated shape corresponding to said corrugated configuration of said reinforcement beam, said reinforcement beam being attached directly to said mounting lugs.