Projection welded panel spacer and method for making the same

A method for making a spacer assembly, comprising:

• providing a portion of sheet metal having a plurality of projections formed thereon and extending from an edge thereof;
• roll forming said portion of sheet metal into a tubular configuration with said plurality of projections extending from an end of said tubular configuration;
• positioning said roll formed portion of sheet metal and a metal base member to which said roll formed portion of sheet metal is to be welded in a discharge welding apparatus having a pair of electrodes so that the projections of said roll formed portion of sheet metal contact a surface of said metal base member;
• providing a force so that the projections are disposed in forcible engagement with the surface of said metal base member;
• and
• supplying an electrical current between the pair of electrodes and through said roll formed portion of sheet metal and said metal base member to enable the projections to reach a molten metal stage and be subsequently solidified so that the roll formed portion of sheet metal is welded to said metal base member;
• said method characterized in that said plurality of projections are formed on said portion of sheet metal before said portion of sheet metal is roll formed into said tubular configuration.