Just a thought.., They have that styrafoam or some kind of insulation material in a can that you shake and shoot out of a can.
Perhaps you can use wax paper around the hulls and make a form out of the stuff.
Who knows, it may work.
Rick
I've tried to use that stuff for molds before - it really doesn't have much structure too it and I crushed it with some really light vacuum bagging. It might suffice for some light duty padding for something - but it would flatten pretty quickly with boat weight.
