Abstract: Personal watercraft and personal watercraft fabrication using a thermoforming process are described. The personal watercraft manufacturing process includes a set of molds, thermoforming equipment, and thermal formable materials. The process greatly reduces manufacturing costs, decreases manufacturing time, increases part consistency and tolerances, offers better performance characteristics and durability and results in less environmentally harmful deposits and waste.

Abstract: The various example embodiments disclosed herein pertain to an internal support structure in a watercraft that interfaces the motor to the hull and decreases the weight of the hull, by eliminating various components. The various example embodiments add structural stability to the overall structure of the hull or body, allowing for thinner hull and deck material. This chassis consists of a metal, composite, and or plastic bent or formed tubular structure that outlines the internal dimensions of the hull. The motor is able to mount to this structure so that the body is no longer the direct point of attachment. This furthers the structural stability and reliability of the hull as it disperses forces over a larger area and mounts to a means more suitable than direct hull mounts, which often shear and break loose from the traditional fiberglass hulls. By mounting the engine to this chassis, the hull can be completely removed without disassembling and other components.