Abstract: A method for expanding tubular blanks includes pre-expanding or initially expanding a section of the tube by forcing a punch into an open end of the tube. The punching process may be repeated to achieve up to approximately 50% expansion from the original configuration of the blank. Then, the same pre-expanded section can be further expanded by hydroforming such that the blank is filled with pressurized fluid to achieve further expansion of the initially expanded section up to approximately 100% expansion from the original configuration of the blank. As a final step, the open end of the expanded tube may be cut to its ultimate shape.

Abstract: A method for forming a hollow part (18) that allows the use of hydroforming in cases where the part interconnects between sections having extreme variations in cross-section. A complete hollow part (18) is formed by joining a hydroformed hollow section with hollow sections. A method for securing a fastener sleeve (102) insert in a pre-fabricated hollow part (100) is also provided. In this method, the hollow part (100) is deformed slightly to form flanges (108) that secure the insert (102) in the part. Once the insert (102) is secure in the hollow part, fasteners can be applied to the part without collapsing it.

Abstract: A method for expanding tubular blanks includes pre-expanding or initially expanding a section of the tube by forcing a punch into an open end of the tube. The punching process may be repeated to achieve up to approximately 50% expansion from the original configuration of the blank. Then, the same pre-expanded section can be further expanded by hydroforming such that the blank is filled with pressurized fluid to achieve further expansion of the initially expanded section up to approximately 100% expansion from the original configuration of the balnk. As a final step, the open end of the expanded tube may be cut to its ultimate shape.

Abstract: An assembly of supporting members includes a first member overlapping a second member and positioned within a hollow interior of the second member. The hollow interior of the second member has a flange on which the first member rests. A leading edge of the first member may have a protrusion extending away from the first member towards the flange of the second member to protect the flange and the connection between the first and second members. The first and second members may be hydroformed with the protrusion being an integral element of the first member.

Abstract: A method for forming a hollow part (18) that allows the use of hydroforming in cases where the part interconnects between sections having extreme variations in cross-section. A complete hollow part (18) is formed by joining a hydroformed hollow section with hollow sections. A method for securing a fastener sleeve (102) insert in a pre-fabricated hollow part (100) is also provided. In this method, the hollow part (100) is deformed slightly to form flanges (108) that secure the insert (102) in the part. Once the insert (102) is secure in the hollow part, fasteners can be applied to the part without collapsing it.

Abstract: An assembly of supporting members includes a first member overlapping a second member and positioned within a hollow interior of the second member. The hollow interior of the second member has a flange on which the first member rests. A leading edge of the first member may have a protrusion extending away from the first member towards the flange of the second member to protect the flange and the connection between the first and second members. The first and second members may be hydroformed with the protrusion being an integral element of the first member.

Abstract: A device for mounting a vehicle component to a vehicle frame member. The device including a mounting spacer assembly having outer and inner mounting spacer structures and a plurality of parallel elongated fasteners. The outer mounting spacer extending through an opening in the vehicle frame member and the central exterior peripheral portion being welded to the frame member. The inner mounting spacer structure being secured within the outer mounting spacer structure in a rattle-free condition. The plurality of parallel elongated fasteners each having a shank configured at one end to engage the vehicle component and having a head at the opposite end. The mounting spacer assembly further including a plurality of longitudinally extending structural portions disposed in generally surrounding relation with each of the fastener shanks and in force transmitting relation between the vehicle component and each of the heads.