Abstract: A method of forming a motor vehicle instrument panel with a flexibly tethered air bag deployment door includes the steps of molding an instrument panel with a first plastics material to a desired shape and with an integral air bag deployment door whose opening is defined by a tear seam formed by a groove molded in one side of the panel and with an integral mounting/hinge flange that extends from an inside surface of the door, and forming a bonded layer of second plastics material on one side of the flange and the inside surface of a potentially frangible portion of the door.