Frame assembly and method of making

A frame assembly comprising:

• a track having a base wall and a pair of opposed track side walls extending away from opposite sides of said track base wall,
• a curved wall section with an inside radius extending between each side of said track base wall and said track side walls,
• a stud having a stud base wall and a pair of opposed stud side walls extending away from opposite sides of said stud base wall, said stud base wall and stud side walls having an end edge, said stud having an end portion nested in said track and extending transverse to said track, said stud side walls having a pair of aligned holes, an inwardly projecting hollow rivet stem in each of said holes made by deforming said track side walls into said holes, an end portion of each of said stud side walls being deformed to a curved end section conforming in shape to said inside radius with said end edge of said stud to contact the top surface of said track base wall to hold said stud against movement relative to said track.

A frame assembly having at least one metal stud with a pair of opposed stud side walls fastened inside a metal track with a pair of opposed track side walls, said frame assembly comprising:

• a pair of opposed aligned inwardly extending markings at selected positions in the track side walls in a first assembly position, each said marking having a marking center,
• each stud having an end portion nested in said track, a pair of opposed aligned holes in the stud side walls of said end portion with each marking of each pair being disposed in an adjacent hole with the center of each hole being offset above the center of each marking in the first assembly position,
• each marking being deformed to an inwardly projecting hollow rivet stem to draw the stud into the track and align the hole centers with the marking centers and with the end of the stud being forced firmly against an inside surface of the track base wall in the second assembly position to hold said stud rigidly to said track and against movement relative to said track, said track having a base wall with a raised intermediate section and recessed wall portions on each side of said raised intermediate section with the end of the stud forced against said raised intermediate section, there being gaps formed on each side of the raised intermediate sections and the end of said stud.