Abstract: A method of forming a door panel is accomplished by providing a plurality of spaced rollers. A first plastic facer is drawn beneath the rollers wherein the first facer is in the form of a continuous sheet having an upwardly facing surface. A second plastic facer is drawn beneath the rollers, and is in the form of a continuous sheet and at least a portion of the second facer is spaced above the first spacer. A pair of rails are positioned on opposed sides of the first facer and drawn beneath the rollers. A foam material is deposited on the upwardly facing surface prior to drawing the first facer beneath the rollers. The foam material expands and hardens to adhere together the first facer, second facer and rails into a continuous length of assembled panel.