Method of forming a decorative panel of molded plastic

Claim 1

An improved method of forming a decorative panel of molded plastic comprising the steps of, constructing a form having a realistically detailed surface; covering said detailed surface with a mold release material; applying a thin layer of gel coat over said mold release material; applying a plurality of layers of fiberglass matte and resin over said gel coat layer; allowing said plurality of layers of fiberglass matte and resin to harden thereby forming a mold having a female side being formed against said detailed surface and a side opposite from said female side; removing said mold from said form; perforating said mold with a plurality of small holes thereby providing fluid communication between said female side and said side opposite; providing a vacuum means to said side opposite of said mold; placing a sheet of plastic in a retention means, thereby disposing said sheet above and adjacent said female side of said mold; locking said sheet of plastic in said retention means; activating a heating means, thereby heating said sheet to a pliable state; activating a ram means, thereby placing said mold in a sealed position directly adjacent the pliable sheet of plastic; activating said vacuum means, thereby drawing said pliable sheet of plastic into said female side of said mold; cooling said formed panel; and unlocking said retention means and removing said formed panel from said mold; wherein the step of constructing a form having a realistically detailed surface includes the steps of, constructing a rectangular wooden base; affixing shims of varying thicknesses to the wooden base; and affixing a veneer of authentic material to each shim thereby resulting in a detailed surface duplicating an actual structure comprised of the authentic material.