Abstract: A lightweight composite fairing bar (14) for use in fabricating a composite component (16) of an aircraft. The fairing bar (14) includes a core (18) and an elongated outer shell (20) surrounding the core (18). The outer shell (20) is comprised of a laminate material, and the core (18) is comprised of epoxy syntactic foam having a lower density than that of the laminate material. The outer shell (20) is configured for supporting the composite component (16) during the manufacture of the same.

Abstract: A door or other entryway component of synthetic resin composite construction and closely resembling the appearance of stained real wood. Skin portions of doors and other structures have a surface layer of clear gel coat resin molded to include the texture of a wood grain surface. A subsurface layer adjacent the clear gel coat layer is of pigmented gel coat resin. A structural support layer of the skin is of reinforced resin. Skins of a door or similar article are mounted on frames, and dense micro porous resin foam is provided between the skins to form a solid structure such as a door. Moldings retaining glass panels in openings defined in the door or similar structure are attached to the skins by adhesively fastening the moldings to the skins. Fasteners mounted in the moldings so that there are no plugged holes in the exterior surfaces of the moldings are used to locate the moldings properly with respect to the skins by inserting the fasteners into predrilled holes in the skins.

Abstract: A lightweight composite fairing bar (14) for use in fabricating a composite component (16) of an aircraft. The fairing bar (14) includes a core (18) and an elongated outer shell (20) surrounding the core (18). The outer shell (20) is comprised of a laminate material, and the core (18) is comprised of epoxy syntactic foam having a lower density than that of the laminate material. The outer shell (20) is configured for supporting the composite component (16) during the manufacture of the same.

Abstract: A door or other entryway component of synthetic resin composite construction and closely resembling the appearance of stained real wood. Skin portions of doors and other structures have a surface layer of clear gel coat resin molded to include the texture of a wood grain surface. A subsurface layer adjacent the clear gel coat layer is of pigmented gel coat resin. A structural support layer of the skin is of reinforced resin. Skins of a door or similar article are mounted on frames, and dense micro porous resin foam is provided between the skins to form a solid structure such as a door. Moldings retaining glass panels in openings defined in the door or similar structure are attached to the skins by adhesively fastening the moldings to the skins. Fasteners mounted in the moldings so that there are no plugged holes in the exterior surfaces of the moldings are used to locate the moldings properly with respect to the skins by inserting the fasteners into predrilled holes in the skins.

Abstract: This invention describes synthetic redwood building material fashioned from a silicone mold that was impressioned with a genuine article of redwood and contains an outward layer of photoinitiated polyester clear gel coat, which is used only with the red pigmented gel coat in an intermediate layer of color-bearing polyester gel coat, a second intermediate layer of matting material, a third intermediate layer of honeycomb material and a rearward-facing layer. The invention also includes a method for making said synthetic redwood building material.