A composite blast door, when used as an exterior door of a protected structure, can significantly decrease the risk of life threatening hazards to interior occupants. The composite blast door is composed of outer sheets of steel, intermediate sheets of fiber reinforced polymers (FRP), and a filled core of vaporized aluminum. Rubber gaskets may be used as a buffer layer between the FRP and vaporized aluminum core. Fabrication begins with a door skeleton created from steel framing elements, either hollow structural steel members or channels. Afterwards, the rear panels are attached to the door skeleton in inward order: beginning with the outer steel plate, then the FRP sheet and lastly the optional rubber gasket. The door can now be used as a form to receive the vaporized aluminum filling. After filling, the front panels are attached in the reverse order as the rear panels; rubber first, then FRP, then steel.