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Probably interior and exterior molds filled with expanding spray foam.
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Thats along the same lines that I was thinking. 
strick
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Be careful with the spray can foam for this application. Great Stuff is the brand I'm familiar with. It needs air to cure, and if you inject it into a confined space with no air to set the cure, it will continue to expand with considerable force and may deform your inner or outer shell. May work ok if you inject a little at a time, but I wonder if a two part foam might not work better?