Abstract: A molding process for a variety of structures including sports boards is provided. The process includes steps of: creating a three dimensional CAD image of a product, routing the inside edge of the product in a product blank, routing the outside edge of the product in two cassette halves, routing the product blank, inserting closeout material into the routed areas, shaping the product blank, shaping the cassette halves, placing outer skin material for the product in one cassette half, placing inner skin material for the product in the second cassette half, inserting the shaped product blank in the cassette half, placing inner skin material over the shaped product blank, placing outer skin material over the inner skin material, placing the second cassette half over said outer skin material, thereby forming a cassette package, placing the cassette package between contoured molded jaws, shaping the cassette package, and curing the product.

Abstract: A snow board comprises a runner and a support deck pivotally supported on and above the runner for pivoting about a longitudinal axis thereof.

Abstract: A surfboard is constructed to have a soft deck by forming a lower body of a rigid foam material covered with a fiberglass resin coating and forming a deck insert of resilient foam material secured to the deck of the lower body and covered by a flexible impervious covering. The method of making the surfboard includes the shaping and covering of the lower body, the shaping and application to the upper deck of a resilient foam material and the covering of the foam material with a flexible impervious cover.