Abstract: A blow molding method for use with tubular metal work pieces. The method involves placing a tubular metal component part into a molding tool having an internal molding cavity and at least one access passageway into which the component is inserted. The molding tool is then heated to a temperature between about 1000° F. and 1200° F. and a high pressure gas is injected into the tubular component. The high pressure gas causes the portion of the work component residing within the internal mold cavity of the molding tool to expand and assume the shape of the internal molding cavity. After a cooling period, the component is removed from the molding tool. The process is particularly well suited for forming the end support portions of side rails used with vehicle article carriers, but can be used to form a wide variety of complexly shaped forms from tubular metal workpieces.

Abstract: A blow molding method for use with tubular metal work pieces. The method involves placing a tubular metal component part into a molding tool having an internal molding cavity and at least one access passageway into which the component is inserted. The molding tool is then heated to a temperature between about 1000.degree. F. and 1200.degree. F. and a high pressure gas is injected into the tubular component. The high pressure gas causes the portion of the work component residing within the internal mold cavity of the molding tool to expand and assume the shape of the internal molding cavity. After a cooling period, the component is removed from the molding tool. The process is particularly well suited for forming the end support portions of side rails used with vehicle article carriers, but can be used to form a wide variety of complexly shaped forms from tubular metal workpieces.