Method of manufacturing tubular hollow profile vehicle frame parts

A method for manufacturing a hollow vehicle frame part comprising

• removing material from a first side of a first billet to create a first inner shape of a target vehicle frame and wherein material is removed from the first side of said first billet such that at least one substantially flat faying surface is left on said first side of said first billet adjacent to the first inner shape,
• removing material from a first side of a second billet to create a second inner shape of a target vehicle frame and wherein material is removed from the first side of said second billet such that at least one substantially flat faying surface is left on said first side of said second billet adjacent to the second inner shape,
• bonding the first billet and the second billet together at the faying surfaces on first sides of the first billet and second billet such that the first inner shape and second inner shape face each other,
• wherein after bonding, removing material by machining from the second side of the first billet and from the second side of the second billet to create target outer shape of the vehicle frame part, and further in wherein before bonding forming additional faying surfaces adjacent and at an angle to the faying surfaces on the first sides of the first billet and second billet, which faying surfaces together form a rabbet-type joint at which the first billet and second billet are bonded.