SportSubs are manufactured in different sizes and have been painted in many different colors, in fact they are available in any color a customer wants, but the shape is unmistakably a SportSub. The SportSub hull is constructed of fiberglass. That statement in itself, however, doesn't do justice to the technologies that are incorporated. Fiberglass is a generic term used to describe composite compounds of fiber reinforced plastic resins but there are a wide range of fibers, resins and construction techniques that can make one piece of fiberglass as different from another as tin is from titanium. The SportSub hull is all hand laid using multiple layers of woven and biaxial roving.
Every seam is stepped to a different width at each layer.
All interior components are joined with a curved interface filled with a milled fiber composite to eliminate air pockets. These construction techniques are more expensive and time consuming than those used in most common fiberglass products but are necessary to create a durable hull that can be submerged repeatedly and withstand tropical sunlight for many years. The SportSub is not simply finished with an outer layer of fiberglass gel-coat. It is sculpted and painted in much the same way as a hand built automobile. The paint is formulated to bond permanently to fiberglass yet withstand water immersion and continuous direct sunlight.