an appliance door particularly suited for use as a refrigerator or freezer door includes a hollow , blow molded door slab , and a food storage shell or casing projecting from one wall of the slab . the parts forming the shell are prepared in a first step , e . g ., by blow molding , and then are removably mounted as inserts in registering recesses formed in the bottom of the cavity of one of two plates or sections forming the mold for the door slab . the two mold sections are then closed over a tubular , plastic parison which is then inflated to form in the mold the hollow door slab , portions of one wall of which mold over and around a series of male projections which extend into the mold cavity from the mold inserts , thus causing the shell to be molded to and to project from the slab upon subsequent opening of the mold sections and removal of the slab therefrom . additional mold inserts may be used to create expansion grooves in the slab wall which supports the shell , and the opposite or outer wall of the slab may be curved to reduce undesirable effects of thermal bow .