Patent ID: 8747722

Claim:
A method of forming a one piece, cross bar end support for coupling an end of a cross bar of a vehicle article carrier system to a support rail which is secured to a vehicle outer body surface, the method comprising: providing a mold tool having a cavity and a core member; providing a core which is linearly movable along a first longitudinal axis for coring out a neck portion of the one piece end support, the neck portion being hollow and adapted to receive an end of a cross bar there within; providing an additional core which is moveable in a direction opposite to the core and along a second longitudinal axis which is non-parallel to the first longitudinal axis, for coring out an intermediate portion of the one piece end support adjacent to the neck portion; charging the mold with a molten plastic while the core and the additional core are in first positions; waiting a predetermined time interval for the molten plastic to at least partially cure; after the predetermined time interval has expired, then: moving a first horn pin operably associated with the core in a direction generally perpendicular to the first longitudinal axis to cause movement of the core along the first longitudinal axis into a second position to core out the neck portion; moving a second horn pin operably associated with the additional core to cause movement of the additional core along the second longitudinal axis, at an angle of between 30-60 degrees relative to the first longitudinal axis, into a second position to core out the intermediate portion; the neck portion and the intermediate portion being integrally formed as a single piece component without gap lines; further comprising using the cavity and the core component to form flange portions that extend outwardly from opposite sides of the intermediate portion, the flange portions being adapted to permit securing of the cross bar end support to the support rail; and further comprising using another core to core out a portion of one of the flange portions.