A laminated master panel having a predetermined shape and predetermined dimensions, said panel being dividable into a plurality of smaller, subdivided, laminated panels each of which has a substantially uniform thickness, a predetermined shape, and dimensions that are predetermined proportions of said master panel predetermined dimensions, which comprises:
- (a) a foam core comprising a plurality of separate, rigid, constituent segments each having the same predetermined thickness, measured perpendicularly to the median plane of said foam core, said constituent segments taken together having two parallel, laterally and longitudinally extending, exterior planar surfaces and an outer edge;
- (b) an original perimeter frame including a plurality of separate, rigid, integrally formed members that together define the outer edge of said laminated master panel, each of said plurality of original perimeter frame members abutting said outer edge of said foam core,
- all of said original perimeter members having substantially the same predetermined thickness, measured perpendicularly to the median plane of said frame, as said foam core constituent segments do, and all having an outwardly facing exterior surface with substantially the same surface characteristics;
- (c) at least one principal interior divider member integrally formed of a rigid solid material, said at least one divider member (i) abutting at least one of said constituent segments of said foam core, (ii) having substantially the same thickness, measured perpendicularly to said median plane of the original perimeter frame, as said original perimeter members, (iii) containing at least one separation line that delineates a portion of the perimeter of at least one of said smaller, subdivided laminated panels, each of said subdivided panels having a predetermined shape and dimensions that are predetermined proportions of said master panel predetermined dimensions, and (iv) being severable along said separation line to produce at least one subdivided perimeter member each of which has an outwardly facing exterior surface with substantially the same dimension measured perpendicularly to said median plane of the original perimeter frame, and substantially the same surface characteristics, as said outwardly facing exterior surfaces of said original perimeter members,
- said original perimeter members and said at least one principal interior divider member being secured to each other to form a rigid over-all frame;
- and
- (d) a thin face layer secured (i) to each of said laterally and longitudinally extending exterior surfaces of said foam core, (ii) to said original perimeter members, and (iii) to said at least one principal interior divider member, the borders of each of said face layers coinciding with the outer edge of said laminated master panel that is formed by said outwardly facing exterior surfaces of the members of said original perimeter frame,
- whereby severing said at least one principal interior divider member along its said separation line will produce at least one smaller, subdivided laminated panel, each of which subdivided panels has (i) a predetermined shape, (ii) dimensions that are predetermined proportions of said master panel predetermined dimensions, and (iii) a perimeter that has an outwardly facing exterior surface with substantially the same thickness measured perpendicularly to the median plane of said subdivided panel, and substantially the same surface characteristics, throughout its extent.