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It's scary to think about something at 100,000 psi!
Isn't it though? I think at those kinds of levels the numbers are kind of just abstract. 100,000 psi would take 31 coupes stacked on a 1 square inch spot.
I am sure the experts will chime in but I believe the C5 frame rails are hydraulically formed using fluid pressure to bend and form curves in the steel without heating or welding it.
How do you make an aluminum frame for a unibody car?
You "back-half" the car, by cutting out the frame rails/floorboard/trunk floor, then creating a "frame" for the rear of the car, which includes supporting members for the body panels.....