Abstract: A method of building a tire carcass onto a toroidially expanded building drum core is disclosed which comprises the steps of applying the carcass components onto a cover of the toroidially expanded building drum core at a first diameter D1 while rigidly supporting the sides of the cover with a pair of internal side support mechanisms to form a toroidially shaped uncured carcass. The method of building a tire carcass onto a toroidially expanded building drum core further may employ the steps of: expanding the cover radially by an amount less than 5% greater than the diameter D1 and applying a belt reinforcing structure or a tread and belt reinforcing structure onto the expanded cover to form an uncured tire assembly and may further include the step of curing the uncured tire assembly in a tire curing mold and removing the cured tire assembly from the mold; collapsing the toroidially expanded building drum core; and removing the tire from the collapsed core.

Abstract: A method of manufacturing an annular toroidially-shaped cord reinforced ply for a tire is described. The method involves applying an elastomeric layer on a toroidal surface and placing and stitching one or more cords in continuous lengths onto the elastomeric layer in predetermined cord paths. The method further includes dispensing the one or more cords from spools and guiding the cord in a predetermined path as the cord is being dispensed. Preferably, each cord is held against the elastomeric layer after the cord is placed and stitched and then indexing the cord path to a next circumferential location forming a loop end by reversing the direction of the cord and releasing the held cord after the loop end is formed and the cord path direction is reversed. This method allows the step of forming loop ends to occur at more than one diameter on the toroidal surface.