Apparatus, systems and methods for assembling an audio plug with a cosmetic hard shell are provided. A plug may be coupled to a cable. An inner member may be molded about an end portion of the plug and an end portion of the cable. A strain relief member may be molded about a portion of the cable such that the strain relief member is adjacent to and substantially flush with the inner member. The seam between the inner member and the strain relief member may be covered by coupling a hard, smooth outer shell over a portion of the inner member and a portion of the strain relief member. Each of the inner member, the strain relief member, and the outer shell may be formed by injection molding, be of a cylindrical shape, and be formed from the same or different materials.