Method of manufacturing engine cradles

A method for forming a structural member, said method comprising the steps of:

• placing a first sheet member having a length dimension greater than a width dimension in a die in a press,
• placing a second sheet member having a length dimension greater than a width dimension in said press, said second member only partially overlapping said first member, said first member only partially overlapping said second member, and the direction of the length dimension of said second member being angled relative to the direction of the length dimension of said first member,
• placing a third sheet member having a length dimension greater than a width dimension in the die, said third member only partially overlapping said second member, said second member only partially overlapping said third member, and the direction of the length dimension of said third member being angled relative to the direction of the length dimension of said second member,
• placing a fourth sheet member having a length dimension greater than a width dimension in the die, said fourth member only partially overlapping said third member and said first member, said third member only partially overlapping said fourth member, said first member only partially overlapping said fourth member, and the direction of the length dimension of said fourth member being angled relative to the direction of the length dimension of said third member and the direction of the length dimension of said first member so that a closed opening is formed between said four sheet members, and
• closing said press, thereby shaping said first, second third and fourth sheet members into a non-planar shape along substantially the entire length thereof.

A method for forming a structural member, said method comprising the steps of:

• placing a first sheet member having a length dimension greater than a width dimension in a die in a press,
• placing a second sheet member having a length dimension greater than a width dimension in said press, said second member only partially overlapping said first member, said first member only partially overlapping said second member, and the direction of the length dimension of said second member being angled relative to the direction of the length dimension of said first member,
• closing said press, thereby attaching said first member to said second member and shaping said first member and said second member such that at least portions of said first and second members in intimate contact with each other have a top, one side wall extending downwardly from said top, another side wall extending downwardly from said top, one flange extending outwardly from said one side wall, and another flange extending outwardly from said other side wall,
• placing said first and second members in a second die in a press,
• placing at least a third sheet member in said second die in overlapping relationship with said flanges of at least one of said first and second members, and
• closing said press, thereby attaching said flanges of said one of said first and second members to said third member and closing substantially all of the interior of said one of said first and second members.

A method for forming a structural member, said method comprising the steps of:

• placing a first sheet member having a length dimension greater than a width dimension in a die in a press,
• placing a second sheet member having a length dimension greater than a width dimension in said press, said second member only partially overlapping said first member, said first member only partially overlapping said second member, and the direction of the length dimension of said second member being angled relative to the direction of the length dimension of said first member,
• closing said press, thereby attaching said first member to said second member and shaping said first member and said second member such that at least portions of said first and second members in intimate contact with each other have a shape having a top, one side wall extending downwardly from said top, another side wall extending downwardly from said top, one flange extending outwardly from said one side wall, and another flange extending outwardly from said other side wall, wherein said closing step shapes each of said first and second sheet members into said shape along substantially the entire length thereof,
• placing said first and second members in a second die in a press,
• placing first and second closing sheet members in said second die, each of said first and second closing sheet members being in overlapping relationship with said flanges of a respective one of said first and second members, and
• closing said press, thereby attaching each of said flanges to the respective closing sheet member and closing substantially all of the interior of said first and second members.

A method for forming a structural member, said method comprising the steps of:

• placing in a die in a press a first elongated sheet member having a longitudinal axis,
• placing in said die a second elongated sheet member having a longitudinal axis transverse to said longitudinal axis of said first member, said second member only partially overlapping said first member, said first member only partially overlapping said second member,
• closing said press, thereby attaching said first member to said second member and forming each of said first member and said second member into a shape along substantially the entire length thereof such that each of said member has a top, one side wall extending downwardly from said top, another side wall extending downwardly from said top, one flange extending outwardly from said one side wall, and another flange extending outwardly from said other side wall,
• placing said first and second members in a second die in a press,
• placing first and second closing sheet members in said second die, each of said first and second closing sheet members being in overlapping relationship with said flanges of a respective one of said first and second members, and
• closing said press, thereby attaching each of said flanges to the respective closing sheet member and closing substantially all of the interior of said first and second members.

A method for forming a structural member, said method comprising the steps of:

• placing in a press first and second sheet members, said second member only partially overlapping said first member, said first member only partially overlapping said second member,
• closing said press, thereby securing said second member to said first member and forming at least said first member into a shape along substantially the entire length thereof such that said first member has a top, one side wall extending downwardly from said top, another side wall extending downwardly from said top, one flange extending outwardly from said one side wall., and another flange extending outwardly from said other side wall,
• placing said first and second members in a second die in a press,
• placing a closing sheet member in said second die, said closing sheet member being in overlapping relationship with said flanges of said first member, and
• closing said press, thereby attaching each of said flanges of said first member to said closing sheet member and closing substantially all of the interior of said first member.