Fiber matrix composite material made from recycled carpet

A method of manufacturing a rigid board composite structural material comprising the steps of:

• (a) comminuting carpet to a particle size less than about 3 centimeters to form a carpet feed stock comprising fiber of claim 21, said fiber having a diameter of about 0.2 mm to 1 cm;
• (b) adjusting the carpet feed stock to such that the content of the feed stock is about 25 to 35 wt % nylon forming a balanced carpet feed stock;
• (c) introducing the balanced carpet feed stock into an extruder having at least one barrel zone temperature greater than about 250° C.;
• and
• (d) extruding the carpet feed stock to form a structural composite comprising fiber dispersed in a fused matrix, the composite having a thickness of about 0.1 to 2 centimeters, a width of about 2 to 200 centimeters and an indeterminate length.