Abstract: A process for fabricating a boat shell having a hull and deck molded together as a unitary piece in a single molding step is provided. A two part mold is provided including a first and a second mold half. Prior to molding the two halves are separated and materials which are used to form the inner layer, core and outer layer of the shell, are laid up within each half. Cooperative inserts are also removably secured to opposing upper and lower edges of the first and second mold halves. The inserts are then removed, a vacuum is created within the mold, and the shell is heated until cured. By overlapping and curing the port and starboard sides, the two sides become molded in a permanent manner such that the deck and hull of the boat are formed together as a unitary boat shell in a single molding step.