Header beam of a vehicle frame and method of forming the same

A method of forming a header beam for a vehicle frame, comprising:

• cutting an extruded member to form a generally straight beam with a length, the beam having a hollow interior with a forward leg and a rearward leg extending within the hollow interior continuously along the length, wherein the beam includes a front flange and a rear flange extending forward and rearward, respectively, from a body portion of the beam;
• securing opposing end portions of the beam with a clamping device;
• stretching and bending the beam to form a three-dimensional curvature in the beam between the opposing end portions, wherein the secured opposing end portions of the beam remain generally straight;
• striking the rear flange to form an elongated cutout that defines rearward projecting members proximate the end portions, wherein the elongated cutout reduces compression in the rear flange upon bending the beam to the curvature;
• and
• attaching the opposing end portions to a pair of A-pillars of the vehicle frame such that the curvature is positioned to span forward and between the pair of A-pillars.

A method of forming a vehicle header, comprising:

• providing a generally straight beam with a hollow body portion;
• securing a beam end with a clamping device that rotates relative to an opposing beam end;
• bending the beam into a windshield curvature, the beam end being free of bending;
• striking a forward extending flange of the beam to form roof panel engaging notches along a windshield curved edge;
• and
• attaching the end to opposing A-pillars.