A method of making a laminated paint roller comprising: helically winding inner and outer strips comprising polypropylene around a mandrel so as to form a pair of helically wound strips, the strips each having an outer surface; advancing the wound strips along the mandrel; applying a layer of adhesive comprising polypropylene onto the outer surface of each of the wound strips (345, 348); and wrapping a strip of composite cover material (250, 325) about the outer strip and over the layer of adhesive, the composite cover material being formed by the steps of: providing a width of porous pile material having a pile side and a fabric underside; advancing the width of pile material with the fabric underside facing up; extruding a polypropylene-based material to form a flowing layer; applying the smoothly flowing layer as a backing layer having a thickness of 254 micrometers (10 mils) to 508 micrometers (20 mils) on the fabric underside of the advancing width of pile material so that the layer has one side that is in contact with the fabric underside of the advancing material and another side that is not in contact with the advancing pile material, the layer being in molten form when it is applied; applying a compressive force to the other side of the layer before the layer hardens and sets, to smooth the other side of the layer of polypropylene, and to urge the layer and the fabric underside of the pile material together, thereby forming a composite material having a smooth or uniformly imprinted non-porous side and a pile side, and wherein the pile is held fast on the composite material; cutting the width of composite material into a strip once the backing layer is no longer in molten form, thereby forming a composite cover material having an inner surface comprising a smooth or uniformly imprinted non-porous polypropylene side and a pile side; and applying a compressive force from outside of the composite cover material to urge the composite cover material, the layer of adhesive and the inner and outer strips together. helically winding inner and outer strips comprising polypropylene around a mandrel so as to form a pair of helically wound strips, the strips each having an outer surface; advancing the wound strips along the mandrel; applying a layer of adhesive comprising polypropylene onto the outer surface of each of the wound strips (345, 348); and wrapping a strip of composite cover material (250, 325) about the outer strip and over the layer of adhesive, the composite cover material being formed by the steps of: providing a width of porous pile material having a pile side and a fabric underside; advancing the width of pile material with the fabric underside facing up; extruding a polypropylene-based material to form a flowing layer; applying the smoothly flowing layer as a backing layer having a thickness of 254 micrometers (10 mils) to 508 micrometers (20 mils) on the fabric underside of the advancing width of pile material so that the layer has one side that is in contact with the fabric underside of the advancing material and another side that is not in contact with the advancing pile material, the layer being in molten form when it is applied; applying a compressive force to the other side of the layer before the layer hardens and sets, to smooth the other side of the layer of polypropylene, and to urge the layer and the fabric underside of the pile material together, thereby forming a composite material having a smooth or uniformly imprinted non-porous side and a pile side, and wherein the pile is held fast on the composite material; cutting the width of composite material into a strip once the backing layer is no longer in molten form, thereby forming a composite cover material having an inner surface comprising a smooth or uniformly imprinted non-porous polypropylene side and a pile side; and applying a compressive force from outside of the composite cover material to urge the composite cover material, the layer of adhesive and the inner and outer strips together.