Abstract: A composite door with a lite utilizes panels with aligned cutouts and a foam retainer member which extends about the cutouts between the panels to effect a seal. The retainer has a mounting portion extending inwardly from the cutout periphery. The lite is disposed in the cutout and it is secured by an external frame which has portions overlying the outer surface of the panel and its marginal portion. A clamp secured to the foam retainer and external frame and clamps the lite to the external frame, and an internal frame has portions overlying the outer surface of the other panel and the marginal portion of the other surface of the lite and conceals the clamp and fastener.

Abstract: A method for the assembly of doors having a pair of skins and a core of synthetic resin forms a first door element including forming a first skin and a peripheral wall to provide an upwardly opening cavity into which a foamable synthetic resin formulation is introduced. A second skin is then assembled over the cavity, and the resultant door assembly is passed through an elongated heating zone while controlling the thickness dimension of the door assembly to expand and cure the resin formulation in the cavity into a cellular resin insulating core and to bond the skins and core. The several steps are conducted seriatim at stations along a conveyor assembly.