Unitary boat hull and methods of manufacture

A method of manufacturing a boat hull comprising:

• a. forming a foam mold of a predetermined shape and size from at least a first piece of foam and a second piece of foam, each comprising at least one face for being adjoined together;
• b. securing said first and second pieces of foam with an alignment member, said alignment member being positioned within a first hole in said first piece of foam and a second hole in said second piece of foam, said first and said second holes positioned on opposing faces being adjoined;
• c. coating said foam mold with at least one layer of reinforcing fiber and resin;
• and performing one or more of the following steps before coating:
• i. cutting into said foam mold at least one C-channel running in a longitudinal or lateral direction within the foam;
• and/or
• ii. placing a hose or wire within the first or second hole;
• and/or
• iii. the alignment member being hollow;
• and/or
• iv. the first or second piece of foam comprising at least two different densities of foam;
• and/or
• v. a top core material being positioned above a seam between the first and second pieces of foam;
• and/or
• vi. a recess being positioned along each of the adjoining faces;
• and/or
• vii. a hose or wire being provided within a C-channel.

A boat hull comprising:

• a. a foam core, said foam core comprising at least a first piece of foam and a second piece of foam;
• b. at least one alignment member positioned between said first and second pieces of foam;
• c. a C-channel positioned on a face of at least one of the first and second piece of foam;
• d. at least one of a conduit, a tube, a hose, or a wire positioned within the C-channel;
• and
• e. at least one layer of fiber impregnated with resin, said at least one layer of fiber impregnated with resin suitable for covering the foam core.