Patent ID: 7059050

Claim:
A method of fabricating a heat exchanger assembly having a core with fins and tubes extending from opposite ends and into openings in tanks at each end of the core and reinforcement members extending along opposite sides of the core with tank caps closing open ends of the tanks, said method comprising the steps of; forming a tank cap with a dished configuration having a bottom for disposition in the open end of the tank and side walls for engaging the interior of the tank for brazing thereto, forming at least one of the reinforcement members integrally with a tank cap via an S-shaped connection portion more narrow in width than the tank cap integral therewith, forming the connection portion with at least one notch therein for defining a bending area, flaring the tank cap outwardly at the connection portion from parallel relationship to the integral reinforcement member, passing the tank cap over the open end of the tank as the tubes of the core are inserted into the openings in the tank, and deflaring the tank cap into the open end of the tank with a side wall thereof engaging the interior of the tank under said connection portion.