Patent ID: 8677599

Claim:
A method comprising: sizing a foam core to form an upper first core portion, the upper first core portion having a concave portion; providing an unformed, malleable epoxy mixture to form a lower second core portion in a first unformed shape; placing the first core portion and the second core portion into a preform having a preform shape; heating the preform so as to cause the epoxy mixture forming the lower second core portion to flow and mold to form a corresponding convex portion in the concave portion of the first core portion to define a second formed shape different from the first unformed shape and wherein the first core portion is formed taller than the second core portion in a heel region and the second core portion is formed taller than the first core portion in a toe region; wrapping the first core portion and the second core portion with fiber tape to create a wrapped preform; stitching the first core portion with a thread, the thread extending between a first wrapped face and a second wrapped face of the wrapped preform; placing the wrapped preform in a mold; heating the mold to bond the first core portion and the second core portion; cooling the mold; and removing the formed structure from the mold.