Method of producing a spark plug via flared tip attachment

A side electrode for a spark plug, comprising:

• a side wire having a first end and a second end;
• an opening proximate to the first end, the opening extending from a first surface of the side wire to a second surface of the side wire, wherein the first surface has a flared portion proximate to the opening;
• and
• an electrode tip secured to the first end of the side wire, the electrode tip having a first member and a second member, the first member and the second member each having a tip portion and a shaft portion, wherein the tip portion of second member is located on the second surface and the tip portion of the first member is secured to the side wire by engaging the flared portion.

A spark plug, comprising:

• an insulator shell;
• a center electrode disposed in the insulator shell such that one end of the center electrode protrudes from the insulator shell;
• a metal shell exterior to the insulator shell;
• a side electrode having a side wire with a first end coupled to the metal shell and a second end facing the protruding end of the center electrode forming a spark discharge gap therebetween, an opening proximate to the first end of the side wire, the opening extending from a first surface of the side wire to a second surface of the side wire, wherein the first surface has a flared portion proximate to the opening;
• and
• an electrode tip secured to the first end of the side wire, the electrode tip having a tip portion and a shaft portion, wherein the tip portion is located on the second surface and the shaft portion is secured to the side wire by engaging the flared portion.