Abstract: A method of making a multi-piece head suspension for a rigid disk drive. The method includes providing a first layer including a mounting region with an integral boss tower attached to a stiffener by one or more positioning tabs; attaching a second layer including a spring region to an interface between the mounting region and the stiffener; attaching a flexure to the stiffener; and removing the positioning tabs. The flexure can optionally be a portion of the second layer.

Abstract: A partially thinned wire support pad of a generally rectangular shape is provided extending laterally from a longitudinal edge of a base plate of a load beam. The support pad is cut from sheet material in one piece with the load beam and, during other manufacturing procedures applied to the load beam, is partially thinned to a thickness less than the thickness of the load beam. In addition to the partial thinning procedure, provides a smooth radiused convex edge is provided for the exterior perimeter of the partially thinned wire support pad. Partial thinning may also be provided to a trough at a base of channel rails to provide an area of reduced thickness to the channel to provide proximal and distal edges of the channel having a smooth well-radiused profile.