Vehicle door beam with reinforced tab and method for making the same

A structural door beam for vehicles, comprising:

• an elongate channel having an open section configuration defined by a central web and at least one side flange extending along one side of the central web and having an outwardly projecting side edge;
• a mounting tab projecting outwardly from said side edge of said side flange, and having a marginal edge surrounding a generally planar mounting surface configured to support a vehicle motion sensor thereon;
• and
• an integral reinforcing flange extending continuously along a predetermined portion of said side edge of said side flange and a predetermined portion of said marginal edge of said mounting tab, and protruding laterally at a predetermined angle relative to said mounting surface of said mounting tab to define an integral buttress which stiffens said mounting tab to avoid inadvertent activation of the vehicle motion sensor mounted thereon.