A method of continuously forming a stabilizer bar

A method (10) of forming a stabilizer bar is provided that includes the steps of roll forming sheet metal coil (16) into a continuous tube. Next, a first portion (24) of the continuous tube is flattened. The first portion of the continuous tube is sheared to define a first end (35). Next, a second portion (26) of the continuous tube is flattened. The continuous tube is sheared at the second portion to define a final unit length with a second end (38) opposite the first end. That is, the length is sheared from the rest of the continuous tube. The final length is the length is needed to form a single stabilizer bar. Finally, the final unit length is deformed into the desired stabilizer bar shape.