Method for making 360 sails on composite doors

Abstract

Apparatus for making composite doors includes means to locate a plastisol skin cover having an integral sail pocket formed therein within a mold cavity having a lid thereon moveable between opened and closed positions. The lid includes a retractable tool for positioning a hollow substrate extension in the sail pocket to both seal against foam leakage into the hollow substrate extension and to center the substrate extension within the pocket for defining a foam reaction space between the pocket and the substrate extension. A method for making integral 360.degree. sails on a composite door includes the steps of casting a fused plastisol skin having an integral 360.degree. sail thereon formed by a pocket with an entry thereto; locating the sail pocket in a mold cavity; closing the mold and thereafter centering a substrate within the mold cavity to form a foam space and to seal the substrate with respect to the plastisol skin to prevent foam leakage through the substrate and thereafter directing foam precursors into the foam space for forming a foam layer therein.