CHARLES R MACCHIONE
Vehicle Board in Richland, PA

6026573, Feb 22, 2000

May 13, 1998

9/078343

Charles R. Macchione - Richland PA

Dana Corporation - Toledo OH

B23P 1512

298972

A method for manufacturing a side rail in a vehicle frame assembly includes the initial step of roll forming flat stock to form a side rail having a C-shaped cross section defined by an upper flange corresponding to the top open side of the C-shape, a lower flange corresponding to the bottom or opposite open side of the C-shape, and a web corresponding to the back of the C shape and connecting the upper flange and the lower flange. The terminal edges of the upper flange and the lower flange define an edge plane that extends generally parallel to a vertical plane defined by the web. A portion of the lower flange is then stamped in a direction parallel to the vertical plane to form a kick-up in portion in the lower flange. The edge plane defined by the edges of the upper and lower flanges in the kick-up portion does not extend at the predetermined relationship relative to the plane defined by the web. Then, a portion of the lower flange in the kick-up portion is removed, such as by trimming with a cutting torch, such that the edge plane defined by the edges of the upper and lower flanges in the kick-up portion again extends at the predetermined relationship relative to the plane defined by the web.