Tubular core assembly having inside-diameter reducing end members secured by mechanical interlocking member

The process for forming a tubular core assembly for a roll of paper or other sheet material comprising:

• providing an elongate hollow cylindrical central core body member comprising a bodywall having opposed ends, a predetermined outside diameter and a predetermined inside diameter;
• providing inside diameter-reducing annular core insert members, each having at least a portion of its outside diameter substantially the same as the inside diameter of said central core body member and each being inserted into one or said opposed ends of said central core body;
• forming at least one aligned bore in a single operation for each of said cylindrical core body ends and the annular core insert member inserted therein;
• providing at least two radially interlocking members having substantially the same outside diameter as the inside diameter of said aligned bores and inserting and securing one of said radially interlocking members in each of said aligned bores in said cylindrical core body end and the associated core insert member so that each core insert member is secured to the inside periphery of the associated end of the central core body in positive interlocking relationship.