The stock two-piece hull mold is temporarily extended for the vertical-transom design of SEDATION 4.  Foil tape is applied over the plywood forms to provide a smooth surface for the molding process.
After careful preparation and waxing with mold-release agents, fabrication of each half begins with spray application of the gel coat.  This custom "Caribe" yellow gel coat requires  twice the thickness (.020") of conventional white gel coats. Click the image to watch a movie of the process:
A layer of polyvinyl ester resin is applied next, as a water-barrier, followed by multiple layers of tri-axial fiberglass cloth and mat.  Kevlar® woven fabric was applied from 8" above the waterline to the keel for puncture protection and additional strength.
More resin and fiberglass are laminated atop the Kevlar® before application of the Nida-Core polypropylene honeycomb core.  Pre-cut honeycomb panels are then installed with a thick layer of resin and flox.  Technicians stomp the panels into place using a technique resembling the hat dance :)
More laminating with resins, tri-axial fiberglass cloth and mat complete the lay-up of each hull-half.  The molds are then rotated vertically and mated.  The two halves are joined with numerous layers of fiberglass, resins, more Kevlar® etc.   Major structural bulkheads are laminated into place, then the entire assembly is allowed to cure for several days, prior to removal from the mold, to enhance stiffness and assure integrity of the hull's form.