Patent ID: 7332115

Claim:
A method for manufacturing vehicle hulls, comprising: applying a protective coating to a bottom mold; applying a protective coating to a top mold; applying a bottom skin coat over said bottom protective coating; applying a top skin coat over said top protective coating; applying a bottom layer of bulk fiberglass over the bottom skin coat; applying a top layer of bulk fiberglass to the top skin coat; applying an adhesive to a top mating portion of a top bonding surface and to a bottom mating portion of a bottom bonding surface; closing the top mold and the bottom mold together, thereby forming a structural connector out of the adhesive between the top mating portion and the bottom mating portion and creating a unitary piece including at least one cavity; forming at least one foam introduction hole through an outer surface of the unitary piece into the cavity in the unitary piece; and introducing foam into the cavity in the unitary piece through the foam introduction hole.