Method for manufacturing a vehicle frame

Abstract

A rear vehicle frame is formed by placing a plurality of sheet members in a die in a press. At least some of the sheet members partially overlap other of the members. The press is then closed, thereby interlocking the members to form a rear vehicle frame having first and second siderails and at least one crossmember extending between the siderails. The method may include other steps and/or features. After the step of forming a rear vehicle frame, the respective rear siderails may be attached to first and second front siderails. The first and second siderails may overlap a portion of the first and second front rails, at least one of the first and second front rails comprising a scallop at the overlapped portion. The front siderails may each have an upper front siderail and a lower front side rail. There may be a step in between the center siderails and the lower front siderails. At least one of the upper front siderails has a scallop at one edge. The front siderails may be lipped, and the front siderails may be open. The front upper siderails may have tapered walls. The center siderail may have a lip that rolls out at a transition to the front siderail. The front siderail may have a tongue that is adapted to be attached to the center siderail. The frame may be a three-part frame, with rear, center and front sections, or it may be a two part frame, with rear and front sections. In a three-part frame, the rear section may connect with the center section in a manner analogous to the manner in which the center section interconnects with the front section.

Dependencies are inferred from the claim text.