Abstract: A method is provided for pultruding a glass reinforced plastic door panel that is field alterable to fit an out-of-true frame. A mixture of reinforcing fibers and resin is pulled through a set of dies to form a panel having a pair of face sheets that are spaced apart by a hinge side stile at one panel edge and a strike, or lock, side stile at the other panel edge. The hinge side stile is arranged perpendicularly to the face sheets to form a closed panel edge, and the strike side stile is formed as a thick-walled structural channel open to the panel side. The pultruded panel is thereafter cut to lengths equal to the desired height of a door panel.

Abstract: A glass reinforce plastic door panel of unitary construction that is field alterable to fit an out-of-true frame is provided. The door panel is arranged with a strike, or lock, side stile formed as a thick-walled structural channel open to the panel side. Alteration of the door is accomplished by trimming the channel walls without otherwise affecting the integrity of the panel. After trimming the channel walls, a flexible cap strip is emplaced within the channel to form a finished door edge.