Seat:
I know that a lot of you will be scratching you heads and wondering if I rode the short bus to school after you see what I went through to construct my seat but it was a great learning experience and I actually had a good time doing it.
While searching for a seat it became evident that there were not very many out there that were in good enough shape to rebuild or the cost were to high.
I decided to construct a replica seat pan using fiberglass and seat foam using expanding foam.
I purchased an old seat and foam on-line because I wanted my finished product to be as close as possible to the original.
The first part of the process was to learn about fiberglass and foam. I want to thank Fibre Glast Development in Ohio and BJB Enterprises in California for the support, training and technical advice. These are two great companies and they really went out of their way to understand what I was doing and advise me on the best methods and products. They even called to say that some products I had chosen might not be correct and made alternate suggestions. One even saved me some money. Kind of unheard of in todays world.
Original seat pan
Covered seat pan in Bondo to eliminate pitting and rust through
Sanded and primed. Ready to make plug
Layed up glass over original pan
Trimmed and mounted plug on base for working
Sanded and primed plug ready for lay up
Took measurements of original foam
Constructed a 2 piece mold to pour foam into. Used my seat pan plug for bottom and used the original foam for the top.
Mixed foam, poured in mold and closed for cure.
De-molded foam
Original foam and new foam top
Original foam and new foam bottom