Method of making plastic ski

Claim 3

In a method as in claim 1, wherein said top subassembly comprises a top plastic running surface and a first strip of aluminum adhered to the underside of said top plastic running surface, said top subassembly being inverted in said mold, said bottom subassembly comprising a plastic bottom running surface having a pair of steel edges adhered to opposite side edges thereof and a second strip of aluminum adhered to the top surface of said bottom running surface, said bottom subassembly being inverted in said mold, and said corrugated laminate is constructed from narrow strips of paper oriented perpendiculr to said top and bottom subassemblies, said corrugated member having a thickness in excess of said desired core thickness whereby the same is partially crushed when said mold is closed while still bearing against said top and bottom subassemblies to space them from each other to said desired core thickness and said foamable thermosetting resin material has glass micro-balloons added thereto.

Claim 4

In a method as in claim 2, wherein said second strip of aluminum has a width less than the spacing between the innermost portions of said steel edges and is spaced therefrom and without direct connection therewith whereby the physical characteristics of said ski structure are adapted to be varied by making small variations in the width of said second aluminum strip, and said corrugated member having a width sufficient to cause some of said narrow strips of paper to bear against said steel edges to prevent buckling of the same, and wherein said strips of compressible porous plastic foam material positioned along opposite sides of said corrugated laminate member space the paper strips thereof inwardly of the sides of said mold.