Ok call me crazy, but I have been working on a new style dock box, actually already made a half dozen , Military grade direct injection plastics, supper lightweight with wheels, locking handles and indestructible With that said, I had the idea of taking a 40ft long by 8 ft wide by 6 ft high molded block and CNC and entire hull with bulkheads and supports, all 1 piece. half the weight or less of tradition layed glass, and 100 times stronger, only drawback is how to paint it !!

what kind of,or brand of cnc machine is large enough to do a project like that one

The machines are not the problem they make huge bridge mills with 5 axis

http://www.youtube.com/watch?v=33GHes6-_wM

http://www.ketco.com/index.html

http://www.dmscncrouters.com/5-axis-...-gantry-models

why not start with something smaller to prove the concept. say a 20 cig, the later style with the pad bottom... or something else in that range?

Then you would have a full size comparison for strength testing. If it's as light as you are saying you might have an 80 mph boat with a stock small block.

http://www.triumphboats.com/construction/process.php
How about injection molding ?

what is the flexural modulus?

Why paint? as long as its all a solid color like white then i say vinyl graphics

gotta love the Bubba Test

http://www.youtube.com/watch?feature...&v=_kp5Yi93ics

This probably worth a look too, but probably requires alot of upfront investment.

http://larsonboats.com/vec.php