Abstract: A golf club comprising an elongated shaft with a lower end for attachment of the club head. The club head comprises a hosel portion for connection of the head to the shaft end, and a main body portion which comprises an enclosed outer wall and a hollow interior chamber. The club further involves the presence of molded material which fills the hollow chamber of the head, this molded material comprising a flexible synthetic plastic foam which bonds to the inner wall surfaces. The manufacturing method involves the filling of the chamber with the foam whereby the foam forms within the chamber. This method may involve the mixing of an aromatic isocyanate with a polyether polyol prior to introduction of the mixture into the chamber. The mixture, which forms a flexible polyurethane foam with the desired bonding characteristics, may be introduced through an axial bore defined by the hosel which opens into the interior of the chamber. The method is preferably applied to the manufacture of metal club heads.