Method of making a one-piece modular door frame glass run channel

DETAILED DESCRIPTION This invention provides a window receiving assembly carried by a frame of a vehicle door.
A metallic channel of rolled steel has a mounting surface an outboard side wall projected from the mounting surface.
The metallic channel defines a window receiving channel having an opening.
The inboard said wall of the metallic channel has a first edge rolled into the window receiving channel defining a lip and the outboard side wall consisting of an upper portion located in proximity to the mounting surface and a lower portion where the lower portion is rolled into the window receiving channel.
A plastic molding is extruded to the lower portion of the channel forming a sealing surface for engaging an exterior surface of the window.
The sealing surface of the molding and the upper portion of the outboard side wall of the metallic channel define a space where the window receiving channel widens compared to the opening of the window receiving channel.
A filler is co-extruded with the plastic molding onto the metallic channel filling the space and is adapted to allow the metallic channel to be bent to conform with the contour of the window without distortion.
The filler is removed after bending to redefine the space.
A weather-strip has a retaining portion received in the void and a tongue received by the lip of the metallic channel for securing the weather-strip to the metallic channel after the metallic channel is bent to the shape of the window and mounted to the frame of the vehicle whereby the weather-strip is adapted to provide a seal with an interior surface of the window and bias the window towards engagement with the sealing surface of the molding.
One object, feature and advantage resides in the provision of a metallic channel of rolled steel having a mounting surface for mounting to a frame and an inboard side wall and an outboard side wall projected from the mounting surface with the metallic channel defining a window receiving channel having an opening and the inboard side wall of the metallic channel having a first edge rolled into the window receiving channel defining a lip and the outboard side wall consisting of an upper portion located in proximity to the mounting surface and a lower portion where the lower portion rolls into the window receiving channel and a plastic molding is extruded to the lower portion of the channel forming a sealing surface for engaging an exterior surface of the window