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.