Abstract: The method of forming a flanged tubular member is accomplished by sizing the tubular blank to the largest cross section circumferential measure of the desired end product and then using a hydro-forming die and process to expand any excess circumferential measure into a flange defining portion of the die cavity to thereby enable the formation of a cross section of lesser cross sectional circumferential measure than the largest cross section. The flange may be trimmed as desired to shorten the length of the flange, in which case, welding or other suitable attachment process may be employed to join the flanges together to strengthen the tubular member.