Abstract: A method for hydroforming a large surface area, double paneled, hollow auto body part, such as a hood, in which the inner and outer panels are concurrently shape formed and seamed structurally together in the same apparatus. A pair of upper and lower dies crush the edges of a double walled blank together between the dies so as to simultaneously clamp, seal, and form the seam. Then, a special face seal and fluid inlet assembly grips and holds the edges of an inlet hole near the center of the blank to allow the interior to be successfully pressurized and expanded.

Abstract: An apparatus allows a robot arm located in from of a body panel to create a spot weld joint located inboard of and behind an edge of the panel. A bracket fixed to the wrist of the robot arm has an open side wide and deep enough to reach around and behind the panel edge, so that an electrode fixed to the bracket can be aligned with the desired weld location. Then, a power cylinder pulls the bracket inward until the electrode hits the weld point, under tension. The electrode then fires to create the joint, and is retracted and moved. The robot arm and wrist remain entirely in front of the panel, and no access holes in the panel are needed to reach the remote weld point.