Double-walled blow-molded article with insertable handle and method for making same

A method of constructing a hinged article, said article comprising a receiving member and a pinned member, said receiving member being a double-walled blow-molded thermoplastic component having an outer wall, an inner wall, and an open-ended receptacle defined by an arcuate pocket positioned opposite an open end, a stationary wall extending from said pocket and facing generally in a first direction, and a deflecting wall positioned opposite said stationary wall, and facing generally in a second direction opposite said first direction, said pinned member including a cylindrical pin having a longitudinal axis, said method comprising the steps of:

• passing said cylindrical pin in a direction generally normal to the longitudinal axis thereof through the open end of said receptacle and into contact with said pocket such that said deflecting wall deflects away from said stationary wall as said pin travels between said deflecting wall and said stationary wall, and such that said deflecting wall recovers toward said stationary wall as said pin contacts said pocket, said passing step being carried out as said receiving member remains at an elevated temperature at which said thermoplastic comprising said receiving member has a first elastic modulus;
• and
• allowing said receiving member to cool to room temperature such that said thermoplastic comprising said receiving member has a second elastic modulus at room temperature that is lower than said first elastic modulus and that enables said deflecting wall to retain said cylindrical pin within said receptacle and enables said pinned member to rotate relative to said receiving member about said longitudinal axis.