Abstract: A durable composite sheet is provided, with a method of manufacturing the composite sheet. The method includes using a crack-resistant reinforcement panel between a gel coat and a reinforcement panel, which may be of lauan or of other materials. At least one outer coat of material is applied onto a mold surface. A barrier layer may be formed on the outer coat, preferably by spraying. At least one coat of a resin material, containing a curable resin and optionally a filler, and a fibrous reinforcement material are applied over the outer coat (over the barrier layer if present) to form a reinforcement layer. The reinforcement panel is applied to the crack-resistant reinforcement layer, and is bonded thereto.

Abstract: A method of manufacturing a composite sheet includes using a porous reinforcement panel of thermoplastic. A mold surface onto which the composite sheet will be formed is provided. At least one outer coat of material is applied onto the mold surface. At least one coat of resin and reinforcement material is applied over the outer coat to form a reinforcement layer. A porous thermoplastic reinforcement panel is applied to the reinforcement layer, and is bonded to the reinforcement layer. An additional coat of resin may optionally be applied onto the reinforcement panel. If the optional coat is applied onto the reinforcement panel, the reinforcement material may or may not be used with resin. Vacuum force or compression force may be applied to the laminate to assist the resin curing and the bonding, or curing may be performed without the application of pressure.