Method of manufacturing foam core moldings

A method of manufacturing an elongate decorative molding having a decorative surface, comprising the steps of:

• (a) placing a flat surface of an elongate foam molding core on an input portion of a flat elongate table, the foam core comprising a flexible resilient expanded polymer foam solid having:
• said flat surface on one side;
• a decorative surface on another side and a cross-sectional profile, the cross sectional profile of the core being proportionally smaller than the desired cross sectional profile of the finished decorative molding, the table including a smooth continuous planar top surface and a longitudinal axis;
• (b) aligning the foam core on said longitudinal axis of the table;
• (c) sliding the foam core on the top surface of the table forwardly along the axis through a coating containment chamber, the coating chamber:
• having a bottom surface defined by the top surface of the table;
• having a rearward opening larger than the core profile;
• side walls and a forward wall which includes a die, the die having a die opening with a profile proportionally larger than the cross sectional profile of the molding core, the die opening having a profile conforming a desired cross sectional profile;
• (d) applying a cementatious liquid coating material to the decorative surface of the molding core as the foam core slides through the coating chamber, the flat surface of the core slidingly engaging the top surface of the table thus being shielded from coating material;
• (e) passing the coated molding core through the die opening on to an output portion of the table top surface;
• and
• (f) curing the coating material after the molding has passed the die.