In one aspect of the present invention, a method is employed to fabricate a roof bow. A first body element and a second body element each have one or more tabs are both formed from a substrate. The tabs of the first body element are clinched to the second body element. The tabs of the second body el
In one aspect of the present invention, a method is employed to fabricate a roof bow. A first body element and a second body element each have one or more tabs are both formed from a substrate. The tabs of the first body element are clinched to the second body element. The tabs of the second body element are clinched to the first body element. An upper cord is clinched to a top edge of the coupled body elements and a lower cord is clinched to a bottom edge of the coupled body elements to form the roof bow.
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1. A method to fabricate a roof bow, comprising: forming a first body element from a substrate, the first body element includes one or more tabs;forming a second body element from a substrate, the second body element includes one or more tabs;clinching the one or more tabs of the first body element
1. A method to fabricate a roof bow, comprising: forming a first body element from a substrate, the first body element includes one or more tabs;forming a second body element from a substrate, the second body element includes one or more tabs;clinching the one or more tabs of the first body element to the second body element, wherein the step of clinching includes punching an indent into the one or more tabs of the first body element and an adjacent portion of the second body element;clinching the one or more tabs of the second body element to the first body element, wherein the step of clinching includes punching an indent into the one or more tabs of the second body element and an adjacent portion of the first body element;clinching an upper chord to a top edge of the first and second body elements, wherein the step of clinching includes punching an indent into the upper chord and an adjacent portion of the first and second body element; andclinching a lower chord to a bottom edge of the first and second body elements, wherein the step of clinching includes punching an indent into the upper chord and an adjacent portion of the first and second body element. 2. The method according to claim 1, further comprising forming a round aperture in one or more of the first body element and the second body element. 3. The method according to claim 1, further including forming an oval aperture in one or more of the first body element and the second body element. 4. The method according to claim 1, further comprising forming a rectangular aperture in one or more of the first body element and the second body element. 5. The method according to claim 1, wherein the upper chord is formed by extrusion. 6. The method according to claim 1, wherein the lower chord is formed by extrusion. 7. The method according to claim 1, wherein one or more of the upper chord and the lower chord have a T-shaped profile. 8. The method according to claim 1, wherein the clinching is accomplished via a tog-l-loc. 9. The method according to claim 1, wherein the first body element and the second body element are tapered from a side with tabs to a side distal the side with tabs. 10. The method according to claim 1, further comprising forming plural apertures in one or more of the first body element and the second body element, wherein the plural apertures have rolled edges to provide a smooth perimeter edge. 11. The method according to claim 1, wherein the body elements have a substantially arcuate profile. 12. The method according to claim 1, wherein the body elements have the one or more tabs formed at a widest portion of the body elements. 13. The method according to claim 1, wherein the first body element has a feature on a side distal to the tabs wherein the profile of the body element steps down to the end distal the tabs. 14. The method according to claim 1, wherein the second body element includes a cut out that extends to an outside edge distal the side with the tabs. 15. A method to fabricate a roof bow, comprising: providing a first body element and a second body element, the first body element and second body element each having a profile including a first end and a second end joined by top and bottom edges, wherein the first body element and the second body element each have a length less than a length of the roof bow;coupling the first end of the first body element to the first end of the second body element by clinching a portion of the first end overlapping a portion of the second end, wherein clinching includes a step selected from the group consisting of punching an indent into the overlapping portion of the first body element and the overlapping portion of the second body element, driving a fastening element through the overlapping portion of the first body element and the overlapping portion of the second body element, and applying an adhesive, epoxy, or weld to join the overlapping portion of the first body element to the overlapping portion of the second body element;providing an upper chord and a lower chord, and attaching the upper chord and the lower chord to the first and second body elements; andwherein the upper chord and lower chord are attached to the first and second body elements by overlapping a portion of the upper chord over the top edge of the first and second body elements and overlapping a portion of the lower chord over the bottom edge of the first and second body elements, clinching the overlapping portions of the upper chord and lower chord and first and second body elements, wherein the step of clinching includes punching plural indents in each of the overlapping portions of the upper chord and lower chord, wherein one of the plural indents in the upper chord and the lower chord extends to form a corresponding indent in the first body element and another of the plural indents in the upper chord and lower chord extends to form a corresponding indent in the second body element.
Djavairian David (Rochester Hills MI) Freeman Richard B. (Oxford MI) Kansier Earl E. (Lake Orion MI) Ritchie Jack J. (Washington MI), Composite door assembly.
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