Method of making an instrument panel assembly

A method of making an instrument panel assembly comprising:

• forming to substantially final form an instrument panel substrate having a longitudinal edge formed with an elongated door-receiving notch,
• forming to substantially final form a door substrate of greater width than the notch and having flexible opposite sides,
• attaching the door substrate to the instrument panel substrate so that the door substrate covers the notch and so that its opposite sides extend beyond the notch and overlie portions of the instrument panel substrate,
• forming to substantially final form a single decorative cover layer having a main portion for covering the instrument panel substrate and an integral extension for covering the door substrate,
• placing the attached substrates in one-half of a two-part mold and placing the cover layer in the other half of the mold so as to provide a first space between the attached substrates and the cover layer and with the main portion of the cover layer confronting the instrument panel substrate and the extension thereof confronting the door substrate and to provide second and third spaces defined respectively between the opposite sides of the door substrate and the portions of said instrument panel substrate overlain by said opposite sides,
• introducing into the first space a foamable material which when set will provide a padding between the instrument panel substrate and main portion of the cover layer and the door substrate and extension of the cover layer, setting the foamable material to provide a foam padding as aforesaid, and
• bracing the opposite sides of the door substrate to prevent collapse or distortion of said opposite sides by the pressure exerted thereon due to the setting of the foamable material.