Patent ID: 6986205

Claim:
A method of making a composite structural member comprising: providing an elongated flange having a pocket, the pocket formed by two side walls extending from a base wall; the flange having no fasteners formed therein: providing an elongated web having opposed narrow edges; mounting a portion of the web within the pocket of the flange with one edge of the web abutting the base wall of the flange to form an elongated, assembled unit; feeding the assembled unit in a longitudinal direction the unit passing a first station while being fed longitudinally and forming fasteners from the side walls of the flange while the side walls are diverging from the web at the first station, the fasteners integral with the side walls, and the unit immediately passing a second station after leaving the first station while being fed longitudinally, moving the side walls against the web at the second station to press the integral, formed, fasteners into the web to securely join the flange to the web.