Abstract: A grab handle and bezel assembly includes a bezel and a grab handle capable of being received within the bezel. The grab handle is generally non-circular in cross section for properly locating the grab handle within the bezel and for preventing rotation of the grab handle. For example, the grab handle can be D-shaped in cross section having an arcuate surface portion defining a Class “A” surface that is visible to an occupant, and a flat surface portion defining a Class “B” surface that is not visible to the occupant. In this manner, an amount of Class “A” surface treatment of the grab handle can be minimized, thereby reducing the cost of the grab handle and bezel assembly. The grab handle and bezel assembly can securely mounted to a trim component, such as a door bolster, by disposing opposite ends of the grab handle between opposing walls of the bezel and passing a fastener through the door bolster, the bezel and the grab handle.

Abstract: An improved method of forming a vehicle trim part includes the initial step of securing an insert to a vinyl skin in a vacuum mold. The cloth insert is attached to the outer face of the skin, and the two are then placed into a foam mold as a single preform. In this way, if the cloth is improperly connected to the skin, the part can be identified as scrap before foam is injected to complete the part. Once the preform is moved into the foam mold, foam is injected behind the part. Since the preform is positioned within the mold as a single part, the invention more accurately positions the insert and skin relative to the mold prior to foam injection. Again, this improves the quality and appearance of the vinyl part.