A method of manufacturing an elongated article is recited to include extruding a first and a second layer each having peripheries. The second layer is spaced apart from and opposed to the first layer. Together, they define a cavity between them. Into that cavity particles are dispensed. The particles are expanded with an expansion fluid to form an in-situ foam core and to thermally bond the in-situ foam core to the first and second layers. The first and second layers having the thermal bond to the in-situ foam core are shaped to form the article. An elongated article from this process is also recited.