Vehicle door panel with integral handle and method of manufacture

A door panel includes a support having a formed area with opposing spaced apart structures and an elongated reinforcement spanning between the opposing spaced apart structures and spaced from the formed area. A flexible cover is positioned on the support including a main panel section covering the support and covering the formed area, and a second panel section wrapped around the reinforcement for covering the reinforcement to form a handle on the door panel. As molded, the flexible cover includes inner, middle, and outer panel sections that are spaced apart to facilitate molding. The outer panel section is convexly shaped and can be inverted so that it abuts the middle panel section. The door panel is constructed by positioning the flexible cover on the support, and flexing the outer panel section inwardly so that a handle-covering portion of the flexible cover completely surrounds the reinforcement. Thereafter, the flexible cover is RF welded so that the reinforcement is covered and so that a portion of the flexible cover can be removed to form an opening under the handle. Then, flexible foam is injected between the support and the flexible cover. Modifications are disclosed wherein the support is constructed from a smaller support section attached to a larger support section, wherein a rigid foam forms the entire support, and wherein the reinforcement is a loop of stiff material attached to a support.