Patent ID: 7527307

Claim:
A method of making a door handle assembly, said method comprising the steps of: placing an inlay decorative film into a mold; molding a cap in the mold about the inlay thereby creating a thermo-formed cap, said cap including a first blunted end and a second end having a lip; securing the cap to a handle to provide a handle subassembly, such that said first blunted end of said cap is positioned over and about a mating end of said handle, and said cap is pivoted about said end of said handle until said lip of said cap snapably secures around a mating edge of said handle, said handle subassembly including a counterweight housing; placing a counterweight in the counterweight housing to abut the cap; placing the handle subassembly in a handle pivot housing, wherein the handle pivot housing includes a bumper wall having a first mating member; positioning a bumper between the counterweight housing and the bumper wall of the handle pivot housing to provide a cushioned barrier for the handle; and securing the bumper with a second mating member on the bumper through mating engagement of the first mating member and the second mating member, so as to secure the bumper to the bumper wall proximate the counterweight.