Methods for determining a minimum weld distance for adhesives

A method for assembling a frame comprising:

• fitting an interconnecting member about a cross member;
• applying an adhesive to the cross member and interconnecting member;
• and
• welding the interconnecting member to a side rail at a weld location spaced at least a threshold distance from the adhesive, the threshold distance corresponding to a minimum distance based on test data, wherein at the minimum distance a sensor remained below a threshold temperature during a test weld.

A method of assembling a vehicle frame, the method comprising:

• applying an adhesive to an adhesive zone on at least one of a first tubular member and a second tubular member;
• fitting the second tubular member about the first tubular member;
• and
• welding one of the first tubular member and second tubular member to a third tubular member, where the welding comprises selecting a weld line displaced at least a threshold distance from the adhesive zone, the threshold distance corresponding to a minimum distance based upon a rate of heat transfer through the first and second tubular members from the weld line to the adhesive zone.

A method of testing tubular members, comprising:

• selecting a cross member, interconnecting member, and side rail,
• fitting the cross member about the interconnecting member;
• applying an adhesive to the cross member and interconnecting member;
• disposing thermocouples at a plurality of distances from a test weld location, the test weld location being selected to weld the interconnecting member to the side rail;
• welding the interconnecting member to the side rail at the test weld location;
• monitoring temperatures of the thermocouples at the plurality of distances from the test weld location while welding;
• and
• selecting a weld distance corresponding with the least distance from the weld location to a thermocouple at which a temperature reading remained below a threshold temperature while welding.