It’s starts with making molds.

After spraying gelcoat into the mold, lay down fiberglass and strategically place foam, for stiffness and weight savings.

Above, the deck lying upside down in mold. Below, the same deck two days later being resin infused (cover in plastic and vacuum the resin to spread evenly throughout the whole deck).

The infusion process completes in 90 minutes. If not done properly, it must be remade. Below, the future look (right side up and out of mold)…

Davali’s hull waits impatiently, anticipating love at first sight.