Patent ID: 8414724

Claim:
A method of making a structural member, comprising the steps of: forming an inner composite tube wall portion having a first end and a second end comprising a lay-up of uncured composite material, forming comprising wrapping a plurality of uncured plies of a fiber reinforced polymer material onto a mandrel to form, a number of the plurality of uncured plies being wrapped one revolution or less around the mandrel; coupling a first fitting over at least a portion of the first end of the inner composite tube wall portion and curing said inner composite tube wall portion with said fitting in place; forming an outer composite tube wall portion comprising a second lay-up of uncured composite material over at least a portion of the inner tube wall portion and the first fitting following the coupling of the first fitting over at least a portion of the first end of the inner composite tube wall portion and curing said inner composite tube wall portion with said fitting in place; and, co-bonding the inner composite tube wall portion, the outer composite tube wall portion, and the first fitting by curing said second lay-up.