Process for making golf ball having multi-layered cover having a very thin outermost cover layer comprising: providing first and second substantially hemispherical half shells comprising a thermoplastic composition; dispensing uncured liquid thermoset composition into a hemispherical cavity of first half shell; inserting first half of a core subassembly into hemispherical cavity and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms an inner cover layer; dispensing the uncured liquid thermoset composition into hemispherical cavity of second half shell; inserting second half of core subassembly into hemispherical cavity of second half shell and displacing an amount of the uncured liquid thermoset composition such that the uncured liquid thermoset composition forms an inner cover layer and thereby mating the first and second half shells; curing thermoset inner cover layer; and forming dimples in the outer surfaces of mated first and second half shells.