Abstract: A frame for a vehicle chassis includes C-cross section side rails and interconnecting cross members which extend through the vertical webs of the side rails and are attached with connecting brackets to the outside faces thereof. This construction provides the capability of utilizing extended length cross members to which other vehicle components, such as fuel tanks, suspension members, fenders and the like, may be attached.

Abstract: A vehicle frame component, such as a siderail or a cross member, is formed with a generally C-shaped cross section in which the vertical web member has a greatly reduced mass, as compared to a comparable C-channel section of uniform construction. The reduced mass web member has a corresponding reduced effective cross section to substantially reduce the component weight without adversely affecting its vertical stiffness.

Abstract: A vehicle frame assembly, including a pair of sidebars, interconnecting crossbars and optional connecting brackets all formed from channel sections, is manufactured using soft adjustable tooling, preferably a roll former, thereby eliminating the need to use hard tooling. The shorter frame assembly components, including the crossbars and optional brackets, are formed as multi-piece gang members. The frame may be assembled with mechanical fasteners (bolts or rivets) or by welding, the latter obviating the need to use brackets. When mechanical fasteners are used, the components are hole-punched, preferably with numerically controlled piercing equipment. When heat treated steel is used, the piercing and cutting operations are preferably performed after heat treating.

Abstract: A vehicle frame assembly including a pair of side bars, interconnecting crossbars and connecting brackets, all formed from channel sections, is manufactured using a flexible roll former that eliminates the need to use hard tooling. The shorter frame assembly components, including the crossbars and brackets, are formed as multi-piece gang members. The components are hole-punched with numerically controlled piercing equipment, resulting in accurate hole alignment for assembly. For components not requiring offsetting, the component sidebars and bracket and crossbar gang members are preferably heat treated before hole-punching.