Composite engine oil pan and method of making

A composite engine oil pan, comprising:

• a first pan formed of a sheet of metal with a first bottom wall and a first plurality of peripheral walls extending generally upwardly from the first bottom wall, the first plurality of peripheral walls including a first front wall, a first rear wall, and first side walls, the first plurality of peripheral walls terminating in a first peripheral flange extending outwardly from a top of one or more of the first front wall, the first rear wall, and the first side walls, the first pan including:
• an oil sump for containing oil defined by an inner surface extending contiguously along the first bottom wall and the first plurality of peripheral walls and an outer surface opposite the inner surface;
• and
• a second pan formed of a fiber-reinforced polymer resin with a second bottom wall and a second plurality of peripheral walls extending generally upwardly from the second bottom wall, the second plurality of peripheral walls including a second front wall, a second rear wall, and second side walls, the second plurality of peripheral walls terminating in a second peripheral flange extending outwardly from a top of one or more of the second front wall, the second rear wall, and the second side walls, the second pan abutting and bonded to the outer surface of the first pan;
• wherein the second pan is mounted to cover, at least in part, the outer surface of the first pan;
• wherein the second pan is thicker than the first pan by a factor of three or more to structurally reinforce the first pan without abutting the inner surface of the first pan;
• wherein the sheet of metal is press-formed about a mold;
• and
• wherein the second pan is open-molded directly onto the outer surface of the first pan at the first bottom wall and first peripheral walls and along an underside of the first peripheral flange.