Surfboard construction

Claim 1

A METHOD FOR CONSTRUCTING A SURFBOARD COMPRISING: LAYEING COVER LAYERS IN EACH OF TWO MOLDS THAT EACH HAVE SUBSTANTIALLY THE SHAPE OF OPPOSITE HALVES OF A SURFBOARD THAT IS DIVIDED BY AB IMAGINARY VERTICAL PLANE PASSING LONGITUDINALLY THROUGH THE MIDDLE OF A HORIZONTAL SURFVIARDM ABD TGAT EACG GAVE A CAVUTT WUTG A DEOTG AT KEAST TWICE AS GREAT AS THE THICKNESS AT A MIDDLE PORTION THEREOF, INCLUDING APPLYING A THIN LAYER OF WAX-LIKE MATERIAL TO THE MOLD, SPRAYING A GEL COAT WITHIN THE WAX-LIKE MATERIAL, APPLYING FLEXIBLE FIBERGLASS SHEET MATERIAL SATURATED WITH RESIN WITHIN THE GEL COAT, AND SQUEEGEEING EXCESS RESIN FROM WITHIN THE FIERRGLASS SHEET MATERIAL; FILLING EACH MOLD WITH A MOLDABLE MATERIAL TO FORM TWO ELONGATED SURFBOARD PORTIONS, EACH WITH AN INNER SURFACE THAT CAN LIE SUBSTANTIALLY ALONG SAID IMAGINARY PLANE, INCLUDING POURING FOAMABLE MATERIAL INTO THE SHELL FORMED BY SAID COVER LAYER AND ALLOWING IT TO HARDEN, FORMING AN ELONGATED CUTOUT REGION IN THE MOLDING MATERIAL ALONG THE TOP AND BOTTOM OF EACH ELONGATED SURFBOARD PORTION AT THE INNER SURFACE THEREOF TO EXPOSE AN AREA OF THE INNER FACE OF THE COVER LAYER, FILLING THE CUTOUT REGIONS WITH AN EPOXY RESIN ADHESIVE AND ALLOWING IT TO HARDEN AT LEAST PARTIALLY, AND APPLYING A LAYER OF EPOXY RESIN ADHESIVE TO A PUTTY-LIKE CONSISTENCY AND OF A THICKNESS OF MORE THAN ONE-SIXTEENTH INCH TO THE INNER SURFACE OF THE BODY AND TO THE EPOXY ADHESIVE IN SAID CUTOUT REGIONS.

Claim 2

A METHOD FOR CONSTRUCTING A SURFBOARD COMPRISING: LAYEING COVER LAYERS IN EACH OF TWO MOLDS THAT EACH HAVE SUBSTANTIALLY THE SHAPE OF OPPOSITE HALVES OF A SURFBOARD THAT IS DIVIDED BY AB IMAGINARY VERTICAL PLANE PASSING LONGITUDINALLY THROUGH THE MIDDLE OF A HORIZONTAL SURFVIARDM ABD TGAT EACG GAVE A CAVUTT WUTG A DEOTG AT KEAST TWICE AS GREAT AS THE THICKNESS AT A MIDDLE PORTION THEREOF, INCLUDING APPLYING A THIN LAYER OF WAX-LIKE MATERIAL TO THE MOLD, SPRAYING A GEL COAT WITHIN THE WAX-LIKE MATERIAL, APPLYING FLEXIBLE FIBERGLASS SHEET MATERIAL SATURATED WITH RESIN WITHIN THE GEL COAT, AND SQUEEGEEING EXCESS RESIN FROM WITHIN THE FIERRGLASS SHEET MATERIAL; FILLING EACH MOLD WITH A MOLDABLE MATERIAL TO FORM TWO ELONGATED SURFBOARD PORTIONS, EACH WITH AN INNER SURFACE THAT CAN LIE SUBSTANTIALLY ALONG SAID IMAGINARY PLANE, INCLUDING POURING FOAMABLE MATERIAL INTO THE SHELL FORMED BY SAID COVER LAYER AND ALLOWING IT TO HARDEN, FORMING AN ELONGATED CUTOUT REGION IN THE MOLDING MATERIAL ALONG THE TOP AND BOTTOM OF EACH ELONGATED SURFBOARD PORTION AT THE INNER SURFACE THEREOF TO EXPOSE AN AREA OF THE INNER FACE OF THE COVER LAYER, FILLING THE CUTOUT REGIONS WITH AN EPOXY RESIN ADHESIVE AND ALLOWING IT TO HARDEN AT LEAST PARTIALLY, AND APPLYING A LAYER OF EPOXY RESIN ADHESIVE TO A PUTTY-LIKE CONSISTENCY AND OF A THICKNESS OF MORE THAN ONE-SIXTEENTH INCH TO THE INNER SURFACE OF THE BODY AND TO THE EPOXY ADHESIVE IN SAID CUTOUT REGIONS.

Claim 3

A method for constructing a surfboard comprising : laying cover layers in each of two molds that each have substantially the shape of opposite halves of a surfboard that is divided by an imaginary vertical plane passing longitudinally through the middle of a horizontal surfboard; filling each mold with a moldable material to form two elongated surfboard portions, each with an inner surface that can lie substantially along said imaginary plane; forming an elongated cutout region in the molding material along the top and bottom of each elongated surfboard portion at the inner surface thereof to expose an area of the inner face of the cover layer; and applying a layer of adhesive to the inner surfaces of the two surfboard portions to join them, including filling the cutout regions with adhesive.

Claim 4

A method for constructing a surfboard comprising : laying cover layers in each of two molds that each have substantially the shape of opposite halves of a surfboard that is divided by an imaginary vertical plane passing longitudinally through the middle of a horizontal surfboard; filling each mold with a moldable material to form two elongated surfboard portions, each with an inner surface that can lie substantially along said imaginary plane; forming an elongated cutout region in the molding material along the top and bottom of each elongated surfboard portion at the inner surface thereof to expose an area of the inner face of the cover layer; and applying a layer of adhesive to the inner surfaces of the two surfboard portions to join them, including filling the cutout regions with adhesive.