Method of forming a kayak having integrally formed hatch flange surrounding a hatch opening

A method of fabricating a kayak having a hull with a recessed cockpit surface and an integrally formed hatch flange surrounding a hatch opening, the hatch flange being substantially parallel to the cockpit surface, comprising the steps of:

• a. providing a mold assembly comprising a first portion and a second portion meeting along a parting line, where inner surfaces of the first and second portions of the mold assembly define an interior cavity generally corresponding to a shape of the kayak;
• b. forming a void defined by the inner surface of the first portion of the mold assembly such that
• i. the void is in communication with the interior cavity of the mold through a passageway defined by the inner surface of the first portion of the mold assembly,
• ii. the void has a recess portion that creates negative draft in the first portion of the mold assembly;
• c. placing polyethylene powder in one of the first and second portions of the mold assembly;
• d. assembling the first and second portions of the mold assembly together;
• e. heating and moving the mold to melt the polyethylene powder and distribute the molten polyethylene onto the inner surfaces defining the cavity;
• g. discontinuing heating and moving the mold to allow the molten polyethylene to solidify into a polyethylene blank in the shape of the cavity;
• f. removing the first portion of the mold assembly from the polyethylene blank;
• and
• g. cutting a hole in the polyethylene blank to form the hatch opening.