Panel door and method of construction

Method of constructing a panel door comprising the steps of:

• a. Constructing a rectangular skeletal frame having outside and inside faces and defining at least one rectangular opening in a central portion thereof, providing a rectangular mold having a design side and sizing said rectangular opening to said mold prior to assembling said skeletal frame as by staples,
• b. laminating a sheet of plywood in a covering relation to said outside face,
• c. simultaneously routing out a central portion of said plywood sheet and a peripheral edge portion of said rectangular opening to form a simulated molding strip around said rectangular opening,
• d. routing out a key groove in said skeletal frame within and around said rectangular opening,
• e. placing said mold in said rectangular opening with said outside face in a down position and said mold design side in an up position and distributing foamable liquid polyurethane over said design side after spraying said design side with a release agent,
• f. placing a sheet of polyvinyl chloride over said inside face,
• g. placing the door in a press under pressure, sandwiched between said polyvinyl chloride sheet and a protective sheet of material on said outside face for a predetermined period of time until said polyurethane expands and hardens,
• h. remove said door from said press and said sheets and mold from said door,
• i. laminate a sheet of polyvinyl chloride over said inside surface.