Method of splicing and products thereof

A method of fabricating a frame adapted for receiving a closure means and adapted for installation in an aperture of a wall, comprising the steps of:

• a. fabricating an elongated metal member having an exterior surface of elongated channel configuration at each end thereof,
• 1. said fabricating step defining the channel at each end of said elongated member by the formation of a pair of spaced flanges which are integral with and upstanding from said exterior surface and which extend in parallel relation to one another in the direction of elongation of said metal member to provide the sides of said channel, the portion of said exterior surface between said flanges being formed to define a flat configuration which comprises the floor of said channel, and
• 2. said fabricating step including the step of shaping the junctions between said flanges and said flat floor of said channel to define a pair of elongated grooves which extend along the opposite edges of said channel floor in facing relation to one another,
• b. bending said elongated member into a closed-loop configuration and to position the opposite ends of said member in abutment with one another thereby to form a circumambiently shaped frame which has a single butt joint therein extending across said frame in a direction transverse to the direction of elongation of said member,
• 1. said bending step including the step of aligning the channels at the opposite ends of said member as well as their respective pairs of flanges and their respective flat floors and their respective elongated grooves to form a single, common-sided, flat-bottomed straight channel which extends across said butt joint,
• c. further fabricating an elongated rectangular metal plate having a width substantially equal to the width of the bottom of said common channel and having opposing elongated edges which are spaced from one another by a distance slightly less than the distance between the sides of said common channel,
• 1. said further fabricating step including the step of shaping said elongated plate into a dihedral configuration wherein a pair of elongated rectangular planar plate sections are provided which are angularly inclined relative to one another about an elongated common bend axis located between and extending substantially parallel to the opposing elongated edges of said plate,
• d. inserting said plate into said common channel in overlapping relation to said butt joint with the common bend axis of said plate being oriented transverse to said butt joint,
• 1. said inserting step including the step of positioning said plate so that its said common bend axis extends across said butt joint with substantially half the length of said plate being located on each side of said butt joint and so that the opposing elongated edges of said plate are disposed closely adjacent to and in comparatively loose engagement with said elongated grooves;
• and
• e. applying a force to the bend axis of said plate in a direction transverse to the floor of said common channel to flatten the portion of said plate overlying said butt joint toward said butt joint and to flatten the adjacent portions of said plate into surface engagement with the flatbottomed floor of said channel thereby to force said opposing edges of said plate further apart and to wedge said plate edges into outwardly directed tight locking engagement with the aligned elongated grooves on opposite sides of said butt joint,
• whereby said member ends are rigidly secured to one another through said plate to maintain the circumambient shape of said frame.