Abstract: A method of surface bonding elements with a two component polyurethane foam, particularly where one of the surfaces to be joined is relatively porous, including contoured fiberglass panels, carpet, foam and fibrous paneling and the resultant bonded structure. The method includes spraying the liquid foamable polyurethane in a fine mist under pressure on one of the surfaces to be bonded to form dispersed discrete liquid polyurethane droplets; permitting the polyurethane droplets to foam and expand in discrete foam pods; applying the second surface to be joined while said polyurethane foam pods are between 20% and 60% of full cure; and, completing the cure of the polyurethane foam, preferably under moderate heat and pressure.