A method comprising: (i) forming a reinforcement device by the following steps: forming a first member having a contoured, undulating surface with one or more recesses, trenches, depressions, walls, protrusions, projections, or a combination thereof, forming a second member having a contoured, undulating surface with one or more recesses, trenches, depressions, walls, protrusions, projections, or a combination thereof, wherein the undulating surface of the second member complements the undulating surface of the first member so that the first member and the second member interlace when brought together, applying an adhesive to the first member and the second member; wherein the adhesive is applied to a majority of the contoured, undulating surface of the first member, the second member, or both, attaching at least one connecting feature to the first member, the second member, or both, bringing the first member and the second member together to form a clam-like structure, locking the first member and the second member with the at least one connecting feature, forming a first encasing member and a second encasing member, attaching the first encasing member to the second encasing member to form an encasing around the clam-like structure, (ii) exposing the reinforcement device to electrocoating, wherein the adhesive expands during the electrocoating and bonds the first member to the second member and bonds the clam-like structure to the encasing (5, 6). (i) forming a reinforcement device by the following steps: forming a first member having a contoured, undulating surface with one or more recesses, trenches, depressions, walls, protrusions, projections, or a combination thereof, forming a second member having a contoured, undulating surface with one or more recesses, trenches, depressions, walls, protrusions, projections, or a combination thereof, wherein the undulating surface of the second member complements the undulating surface of the first member so that the first member and the second member interlace when brought together, applying an adhesive to the first member and the second member; wherein the adhesive is applied to a majority of the contoured, undulating surface of the first member, the second member, or both, attaching at least one connecting feature to the first member, the second member, or both, bringing the first member and the second member together to form a clam-like structure, locking the first member and the second member with the at least one connecting feature, forming a first encasing member and a second encasing member, attaching the first encasing member to the second encasing member to form an encasing around the clam-like structure, forming a first member having a contoured, undulating surface with one or more recesses, trenches, depressions, walls, protrusions, projections, or a combination thereof, forming a second member having a contoured, undulating surface with one or more recesses, trenches, depressions, walls, protrusions, projections, or a combination thereof, wherein the undulating surface of the second member complements the undulating surface of the first member so that the first member and the second member interlace when brought together, applying an adhesive to the first member and the second member; wherein the adhesive is applied to a majority of the contoured, undulating surface of the first member, the second member, or both, attaching at least one connecting feature to the first member, the second member, or both, bringing the first member and the second member together to form a clam-like structure, locking the first member and the second member with the at least one connecting feature, forming a first encasing member and a second encasing member, attaching the first encasing member to the second encasing member to form an encasing around the clam-like structure, (ii) exposing the reinforcement device to electrocoating, wherein the adhesive expands during the electrocoating and bonds the first member to the second member and bonds the clam-like structure to the encasing (5, 6).