Abstract: A lightweigh resin/glass fiber covered plastic article such as a surfboard. A portion of the upper surface of the article has the ability to withstand exterior surface pressure applied on a small area without damage to the surface thereof. The article has a rigid foam core to which a resilient foam cushion is adhered over which a thin rigid foam sheet is applied and the entire article is coated with a resin and glass fiber layer. The method of making the article is also disclosed herein.

Abstract: A process for fabricating a closed, generally flat plastic object such as a surfboard, in one embodiment comprises the steps of:(a) providing a disassemblable mold having at least four parts comprising a bottom part, a top part and a pair of side rail parts, the interior surface of said mold having the desired shape of the exterior surface of said object;disassembling said mold and applying a clear gel coat to the interior surface of each said mold part;(c) applying laminations of a resin and reinforcing material mixture to each of said mold parts;(d) applying a layer of toluene diisocyanate to at least said top and bottom parts;(e) subjecting said top and bottom parts to a vacuum until said layers of toluene diisocyanate are each firmly adhered to the respective laminations of said mixture;(f) affixing the side rail parts to the bottom part forming a cavity therebetween;(g) coating the interior of the cavity with a resin and reinforcing material mixture;(h) allowing the resin mixture to become structurally s

Abstract: A process for fabricating hollow, foam-filled, reinforced plastic objects such as surfboards. The process involves disassembling a multi-part mold to expose its inner surface. The inner surface is then coated with a gel coat, resin and reinforcing material and assembled into two mold halves. A prefoam material is injected into each mold half which is then capped with a baffle. The foam is then permitted to rise, and a portion of the foam is forced through the baffle. The baffle is then removed and a certain amount of the foam is removed. The two mold halves are joined and a center joining resin is poured in this depression and allowed to cure.

Abstract: An apparatus for securing a fin to the bottom surface of a surfboard and comprising a uniquely configured fin box designed to provide a more secure structural relationship between the fin box and the surfboard. The invention is also designed to provide a more secure means for securing the fin within the fin box to prevent inadvertent loss of the fin while still providing a more advantageous means for releasing the fin from the fin box when removal of the fin is desirable. More specifically, the present invention comprises a fin box of substantially rectangular configuration and designed to be embedded within the underlying surface of the surfboard whereby the exterior surface of the fin box lies flush with the exterior underlying surface of the surfboard. A novel flange integral with the fin box is included to provide added structural resistance to transverse forces that normally occur during surfing which would otherwise tend to cause rotation and loosening of the fin box within the surfboard.