Method of forming a slip joint

A method of forming a slip joint comprising:

• providing a forming mandrel having a plurality of axially extending external splines;
• placing an inner tube circumferentially about the mandrel;
• applying radially inward pressure on the inner tube to deform the inner tube and cause it to conform to the shape of the mandrel, and thereby forming splines on the outer surface of the inner tube;
• applying a circumferential seal around the inner tube;
• placing an outer tube around the inner tube and the seal;
• and
• applying radially inward pressure on the outer tube to deform the outer tube and cause it to conform to the shape of the inner tube, thereby forming splines on the inner surface of the outer tube, and further to form an annular groove on the inner surface of the outer tube that encases the seal, wherein the splines on the outer surface of the inner tube and the splines on the inner surface of the outer tube are configured to cooperate together to form a slip joint.

A method of manufacturing a slip joint comprising:

• (a) providing a first member having a splined portion and a non-splined portion;
• (b) disposing a seal in an axially overlapping manner relative to the non-splined portion of the first member;
• (c) disposing a second member in an axially overlapping manner relative to the splined portion and the non-sp lined portion of the first member;
• and
• (d) deforming a first portion of the second member into engagement with the splined portion of the first member so as to provide a splined portion on the second member that allows the second member to move axially relative to the first member, and deforming a second portion of the second member into engagement with the seal and the non-splined portion of the first member.