Apparatus and methods for modifying a stress skin panel

Abstract

A modified stress skin panel includes a stress skin panel and at least two substantially vertical studs which are molded into the stress skin panel during manufacture or inserted after manufacture. An opening is formed between two substantially vertical studs for insertion of a window, door, or other item. A header stud may also be attached to two of the at two substantially vertical studs to support a load above the opening. A stress skin panel stud inserter includes a stud guide assembly, a heater element, a heater controller, a pair of rails, and a pair of clamps. A second embodiment of a stress skin panel stud inserter utilizes a stud heater element which is attached to a bottom of the stud. A third embodiment of a stress skin panel stud inserter includes a hot air shroud and an alignment jig. The hot air shroud is attached to a bottom of the stud and the alignment jig is used to guide the stud during insertion thereof into the stress skin panel.

I claim:  
     
         1 . A method for modifying a stress skin panel comprising the steps of: 
 (a) providing said stress skin panel having an inner layer sandwiched between two outer layers;    (b) inserting at least two substantially vertical studs into said inner layer; and    (c) forming an opening in said modified stress skin panel for the insertion of a single item between two of said at least two substantially vertical studs, at least one header stud being attached to two of said at least two substantially vertical studs.    
     
     
         2 . The method for modifying a stress skin panel of  claim 1 , further comprising the steps of: 
 (d) providing a heating device which is attachable to a bottom of each said substantially vertical stud that facilitates insertion thereof into said inner layer of said stress skin panel.    
     
     
         3 . The method for modifying a stress skin panel of  claim 1 , further comprising the steps of: 
 (d) heating said at least two vertical studs as thereof are being inserted into said inner layer of said stress skin panel.    
     
     
         4 . The method for modifying a stress skin panel of  claim 1 , wherein: 
 at least one tab being formed on each end of a single said header stud, the single said header stud being joined to each said substantially vertical stud by driving screws through said at least one tab and each said substantially vertical stud.    
     
     
         5 . The method for modified a stress skin panel of  claim 1 , wherein: 
 a support member being placed on top of said modified stress skin.    
     
     
         6 . The method for modified a stress skin panel of  claim 1 , wherein: 
 a top of said inner layer being routed out to receive a support member, said support member being placed on top of said inner layer.    
     
     
         7 . The method for modified a stress skin panel of  claim 1 , wherein: 
 each said substantially vertical stud being fabricated from wood.    
     
     
         8 . The method for modified a stress skin panel of  claim 1 , wherein: 
 each said substantially vertical stud being fabricated from metal.    
     
     
         9 . A method for modifying a stress skin panel comprising the steps of: 
 (a) providing said stress skin panel having an inner layer sandwiched between two outer layers;    (b) inserting at least two vertical studs into said inner layer; and    (c) forming an opening in said modified stress skin panel for the insertion of a single item between two of said at least two substantially vertical studs, a support member being placed on top of said modified stress skin panel.    
     
     
         10 . The method for modifying a stress skin panel of  claim 9 , further comprising the steps of: 
 (d) providing a heating device which is attachable to a bottom of each said substantially vertical stud that facilitates insertion thereof into said inner layer of said stress skin panel.    
     
     
         11 . The method for modifying a stress skin panel of  claim 9 , further comprising the steps of: 
 (d) heating said at least two vertical studs a s thereof are being inserted into said inner layer of said stress skin panel.    
     
     
         12 . The method for modifying a stress skin panel of  claim 9 , wherein: 
 at least one tab being formed on each end of a single said header stud, the single said header stud being joined to each said substantially vertical stud by driving screws through said at least one tab and each said substantially vertical stud.    
     
     
         13 . The method for modified a stress skin panel of  claim 9 , wherein: 
 a top of said inner layer being routed out to receive said support member, said support member being placed on top of said inner layer.    
     
     
         14 . The method for modified a stress skin panel of  claim 9 , wherein: 
 each said substantially vertical stud being fabricated from wood.    
     
     
         15 . The method for modified a stress skin panel of  claim 9 , wherein: 
 each said substantially vertical stud being fabricated from metal.    
     
     
         16 . The method for modifying a stress skin panel of  claim 9  wherein: 
 at least one header stud being attached to two of said at least two substantially vertical studs.  
 
     
     
         17 . A method for modifying a stress skin panel comprising the steps of: 
 (a) providing said stress skin panel having an inner layer sandwiched between two outer layers;    (b) molding at least two substantially vertical studs into said inner layer;    (c) forming an opening in said modified stress skin panel for the insertion of a single item; and    (d) attaching at least one header stud to two of said at least two substantially vertical studs.    
     
     
         18 . The method for modifying a stress skin panel of  claim 17 , wherein: 
 at least one tab being formed on each end of a single said header stud, the single said header stud being joined to each said substantially vertical stud by driving screws through said at least one tab and each said substantially vertical stud.    
     
     
         19 . The method for modified a stress skin panel of  claim 17 , wherein: 
 a support member being placed on top of said modified stress skin.    
     
     
         20 . The method for modified a stress skin panel of  claim 17 , wherein: 
 a top of said inner layer being routed out to receive a support member, said support member being placed on top of said inner layer.    
     
     
         21 . The method for modified a stress skin panel of  claim 17 , wherein: 
 each said substantially vertical stud being fabricated from wood.    
     
     
         22 . The method for modified a stress skin panel of  claim 17 , wherein: 
 each said substantially vertical stud being fabricated from metal.    
     
     
         23 . A method for modifying a stress skin panel comprising the steps of: 
 (a) providing said stress skin panel having an inner layer sandwiched between two outer layers;    (b) molding at least two vertical studs into said inner layer;    (c) forming an opening in said modified stress skin panel for the insertion of a single item; and    (d) placing a support member on top of said modified stress skin panel.    
     
     
         24 . The method for modifying a stress skin panel of  claim 23 , wherein: 
 at least one tab being formed on each end of a single said header stud, the single said header stud being joined to each said substantially vertical stud by driving screws through said at least one tab and each said substantially vertical stud.    
     
     
         25 . The method for modified a stress skin panel of  claim 23 , wherein: 
 a top of said inner layer being routed out to receive a support member, said support member being placed on top of said inner layer.    
     
     
         26 . The method for modified a stress skin panel of  claim 23 , wherein: 
 each said substantially vertical stud being fabricated from wood.    
     
     
         27 . The method for modified a stress skin panel of  claim 23 , wherein: 
 each said substantially vertical stud being fabricated from metal.    
     
     
         28 . The method for modifying a stress skin panel of  claim 23  wherein: 
 at least one header stud being attached to two of said at least two substantially vertical studs.