Patent ID: 7185618

Claim:
A method for manufacturing a sheet metal rocker arm having substantially enhanced relative structural integrity and stiffness comprising (a) bending a sheet metal pattern with window openings to form a longitudinal U-channel with straight sides and a connecting U-portion and wherein the openings align when the pattern is bent said sides and having dimensions generally conforming to a rocker arm, said sheet metal pattern having an outer configuration of a shape and size when bent consistent with said dimensions, (b) inserting a metal tubular member into said aligned window openings, said tubular member being provided with slits that pierce through the metal such that a tab is created by said slits, and when said tab is bent; bending the ends of said tab of the inserted tubular member inwardly into the channel to form a cross member transverse to said sides and such that the ends of said tab abut against the inside of the U-channel sides; and (c) joining said tab ends to the straight sides of the U-channel to integrate said tab and said sides to produce a rigid structure.