Method of forming a grounding point on an aluminum member

A method of providing an electrical grounding point on an aluminum structural member of a motor vehicle. The member is hydro-formed to produce a closed cross-section, after which a hole surrounded by a flange is formed in a wall of the member. The flange is generally the shape of a truncated cone and extends toward an interior of the member. A self-tapping fastener having a grounding lead attached thereto is driven into the hole to cut threads into the flange and secure the grounding lead to the member. The self-tapping fastener allows the grounding connection to be achieved without any access to the hollow interior of the member as would otherwise be required.