Patent ID: 7087132

Claim:
A method of manufacturing a panel for use with a vehicle, comprising the steps of: applying at least one coat of a waxy substance to a substrate, said substrate comprising a mold including an interior having the desired three-dimensional outer shape of said panel; allowing said waxy coat to set; buffing said waxy coat; spraying a coating of a releasable substance on top of said waxy coat; applying at least one coat of gel on top of said releasable substance, said gel coat forming the surface of said panel; drying said gel coat; applying at least one layer of a composite material to said gel coat; wetting said composite material with a resin until said composite material is saturated; rolling out said saturated composite material to remove any air pockets that may have formed between said material and said gel coat during wetting; drying said composite material; removing said composite material from said substrate; wherein the outer shape of said composite material with said gel coat forms the desired outer shape of said panel; and attaching said panel to a portion of a completely assembled vehicle.