Integrated bumper boat hull and method

An integrated bumper boat hull, comprising:

• a. an aluminum hull with opposite side walls;
• b. outer rigid framing formed on said sidewalls, said framing including upper and lower longitudinal frame members attached to said hull and a plurality of intermediate frame members perpendicularly aligned and located between said upper and lower longitudinal frame members, said rigid framing also including an anchor plate spaced laterally from said hull thereby forming a plurality of partly enclosed chambers on said side walls capable of being filled with foam;
• c. a first foam layer formed inside said chambers to cover said immediate frame member and said anchor plate, said foam layer made of made of hard, closed cell polyurethane foam.
• d. a second foam layer covering the exposed surfaces of said first foam layer, said second foam layer is made of soft, closed cell polyurethane foam;
• and,
• e. a hardening protective layer formed over the exposed surfaces of said second foam layer and said upper and lower longitudinal frame members.

A method of manufacturing, comprising

• a. manufacture a hull with outer rigid framing formed on the side walls creating partially enclosed chambers, said framing including a plurality of rigid anchor plates that resist lateral forces applied thereto;
• b. applying a first foam layer into the chambers and covering the rigid anchor plates;
• c. applying a second foam layer over the first foam layer;
• and,
• d. applying a polyurethane hardening layer over the second foam layer.