Patent ID: 8001689

Claim:
A process for forming a variable gauge metal sheet into a desired shape, said process comprising: providing a variable gauge metal sheet having a first surface and a second surface along a longitudinal direction, the metal sheet having a thickness measured at any point on the metal sheet as a distance between the first surface and the second surface, the thickness of the metal sheet being different over a first portion of the sheet than over a second portion of the sheet along a transverse direction, and forming said metal sheet into a first desired shape by bending the metal sheet about a first fold line, said first fold line extending through both the first portion and the second portion, to bring segments of the first surface of the metal sheet on either side of the first fold line into increased opposition with each other, wherein said bending of the metal sheet about the first fold line is effected by holding the metal sheet on a first clamped side of the first fold line secured between a first clamping die and a second clamping die while applying forces to the second surface of the metal sheet on a second moved side of the first fold line, wherein the first clamping die has a first engagement surface which engages the first surface of the metal sheet and is a complementary mirror image to a surface contour of the first surface of the metal sheet that it engages, wherein the second clamping die has a second engagement surface which engages the second surface of the metal sheet and is a complementary mirror image to a surface contour of the second surface of the metal sheet that it engages.