Self-extruded bushing assembly and method of making the same

A method for making a vehicle frame member with a shock absorbing mounting structure to be mounted to another structural component of a motor vehicle, said method comprising:

• providing a tubular member surrounding a hollow interior, said tubular member having a lateral opening formed therethrough and an annular edge portion surrounding said opening, said tubular member having a first opposing surface facing outwardly away from said hollow interior and a second opposing surface facing inwardly towards said hollow interior with a thickness between said opposing surfaces which is relatively small in comparison to the surface areas of said opposing surfaces;
• providing a shock absorbing mounting structure having a mounting portion constructed and arranged to be secured to the structural component of the motor vehicle and a yieldable shock absorbing portion associated with said mounting portion;
• positioning said shock absorbing mounting structure adjacent said first opposing surface and forcing said mounting structure inwardly with respect to said tubular member through said opening such that said mounting structure engages said annular edge portion and deforms said annular edge portion inwardly into the hollow interior of said tubular member to form an annular flange portion that engages an exterior surface of said mounting structure in an interference fit relation so as to securely retain said mounting structure within said opening, thereby enabling said tubular member to be resiliently mounted to the aforesaid structural component;
• and
• supporting a portion of said second opposing surface adjacent said opening while said mounting structure is being forced through said opening such that only said annular edge portion is substantially deformed by said mounting structure.

A vehicle frame member to be mounted to a structural component within a motor vehicle, said frame member comprising:

• a tubular member surrounding a hollow interior, said tubular member having a first opposing surface facing outwardly away from said hollow interior and a second opposing surface facing inwardly towards said hollow interior with a thickness between said opposing surfaces which is relatively small in comparison to the surface area of said opposing surfaces;
• said tubular member having a lateral opening formed therethrough and an annular flange portion which surrounds said opening and projects inwardly into said hollow interior from said mounting portion;
• and
• a shock absorbing mounting structure securely mounted within said opening, with said annular flange portion tightly engaging said mounting structure in an interference fit relation as a result of said mounting structure being positioned adjacent said first opposing surface and forced inwardly through said opening such that said mounting structure engages an annular edge portion of said tubular member surrounding said opening and deforms said annular edge portion inwardly toward said hollow interior to form said annular flange portion;
• said mounting structure having a mounting portion constructed and arranged to be secured to the aforesaid structural component of the motor vehicle and a yieldable shock absorbing portion associated with said mounting portion, said mounting portion being constructed and arranged to enable said mounting structure to be resiliently mounted to the structural component, said shock absorbing portion permitting relative movement between said tubular member and the structural component.