Method for manufacturing a fluid coupling apparatus

A method for manufacturing a fluid coupling apparatus for communicating fluid from a fluid hose to a heat exchanger, the steps comprising:

• providing a substantially cylindrical metallic tube having a first portion and a second portion;
• forming an aperture through a wall of said second portion;
• placing a sphere inside said second portion of said tube and in axial alignment with said aperture wherein the diameter of said sphere is larger than the diameter of said aperture and smaller than the diameter of said second portion of said tube;
• compressing said second portion of said tube to form a substantially rectangular configuration of said second portion and forcing said sphere through said aperture to extrude and form a shoulder extending outwardly from an area of said second portion defining said aperture;
• and
• forming a closed end in said second portion of said tube.

A method for manufacturing a fluid coupling apparatus for communicating fluid from a fluid hose to a heat exchanger, the steps comprising:

• providing a substantially cylindrical hollow seamless welded tube having a first portion and a second portion;
• punching an aperture through a single wall of said second portion;
• inserting a sphere into said second portion of said tube wherein the diameter of said sphere is larger than the diameter of said aperture and smaller than the diameter of said second portion of said tube, and said sphere placed in axial alignment with said aperture;
• placing said tube in a stamping press dye wherein said dye has a substantially rectangular portion formed therein for receiving said second portion of said tube, a substantially cylindrical portion formed therein for receiving said first portion of said tube, and a bore extending though said press dye for receiving said sphere;
• compressing said second portion of said tube to extrude said sphere through said aperture and form a shoulder extending from said second portion for further defining said aperture and to form a substantially rectangular portion of said second portion of said tube;
• cutting relief slots in an open end of said second portion of said tube to form integral tabs therewith;
• folding said integral tabs to form a substantially closed end of said substantially rectangular second portion of said tube;
• and
• brazing a cap onto said integral tabs to form a closed end of said second portion of said tube.