Patent ID: RE42964

Claim:
A method for producing a truck bed toolbox lid comprising: providing a metallic top sheet member having a depending front edge member, a depending rear edge member and depending lateral edge members, wherein an edge perimeter is formed along the depending front, rear and lateral edge members; providing a substantially flat metallic liner sheet member; joining said metallic liner sheet member to said metallic top sheet member in edge contact abutment with said edge perimeter so as to define an internal cavity having a funneled, gas permeable apex boundary; and injecting a self-expanding, self-curing foam into said internal cavity in an amount such that said internal cavity is completely filled upon expansion of said foam, wherein said foam expands toward said funneled, gas permeable apex boundary and cures, such that said foam adheres to said metallic top sheet member and said metallic liner sheet member, and such that said metallic top sheet member, said foam and said metallic liner sheet member form a rigid composite member.