AKFF member Xtian stumbled upon this informative Youtube clip (that is actually a splice from some show on the Discovery channel) that describes the basic process in which polyethylene (or plastic if we want to save ourselves a few syllables) kayaks are constructed. I imagine there are some subtle differences from various companies (for example, I know that Hobie uses a special process to ensure certain parts of the kayak are thicker where required) but this does provide a pretty good rundown of how a kayak is formed from a bunch of powdered plastic. Click the 'read more' link to watch the clip.
