Anyone moulded a seat foam ?

[Grewth]

I'm just weighing up my options.
I've got a seat to refurb, the 50 yr old foam is both hard and brittle now.
I've got the option of buying a ready made (pattern) seat foam, or attempting to make my own.
The You Tube tutorials seem to point to carving down a foam block.
I'm wondering if I could mould a foam like the factory did ?
The pattern item might seem the obvious route, but all too often I've been sadly disappointed by so called "perfect" replicas

 

[miketweedie]

I've done "pattern foam" in my old VW, and it worked as described. For my buddy's café bike I got some high density and some softer memory foam slabs and used both. bottom is higher density and top is memory foam, which holds you in nicely. I just used spray adhesive to hold the layers together, then mounted it to the seat pan and cut with a bread knife. You can shave the tapers you want with sandpaper.

If pre-cut is an option, I'd probably go that route again as the process was simple enough but getting it how you want it isn't the easiest. I probably saved $40 over buying an off the shelf foam kit for his. On my own café bike the seat is 100% custom, so my only option will be to make my own (or have an upholstery shop make it)

 

[WideAWAKE]

I'm just weighing up my options.
I've got a seat to refurb, the 50 yr old foam is both hard and brittle now.
I've got the option of buying a ready made (pattern) seat foam, or attempting to make my own.
The You Tube tutorials seem to point to carving down a foam block.
I'm wondering if I could mould a foam like the factory did ?
The pattern item might seem the obvious route, but all too often I've been sadly disappointed by so called "perfect" replicas

Only way your gonna pour your own “pattern” foam is if you got a mold to pour it into. I’ve made a few (not for seat foam) it’s a ton of work, in no way worth a 1 off.

Build and cut it from a block, or buy one already made.

At least that’s my take on it.

 

[Marlin72xs]

Yes, the youtube stuff is interesting and the use of an electric carving knife appears to work well. I bought some foam , 2 types, to attempt to redo the 72 seat because as you mentioned, after 50 years or so, it looked like I was grating cheese on the battery and tool compartment. I tend to ponder a long time over jobs like this, then Mikes had a blemished seat at a reduced price, so I bought it. It's too hard though. And after riding my Virago, (a very plush saddle, indeed), it feels like a cinder block.
When I find the time, I'm gonna tackle the gluing, cutting and forming the foam I bought! Good luck with yours!

 

[Marlin72xs]

I forgot to mention that when I took my original seat apart, the seat base was rusted badly where it touched the foam. There was no repairing it. That's why I bought the blem from Mikes. The only blem was a bent side mount and the Yamaha across the back was not centered.
Some day I'll get to it! Again, good luck with yours!

 

[Wingedwheel]

I haven’t really looked yet but who sells the pre-formed seat foam? When I get to the ‘77 it’s got the old K/Q with a big mouse hole right in the center. The pan is excellent so I’d prefer to be able to use it. I would have to find a replica cover as well.

 

[Marlin72xs]

Ok, last march I got ambitious and pulled the seat from Mikes apart, bought some 3M heavy duty spray glue, got out my Dad's old electric knife and re-found the foam I bought 7 years ago. I'm not really that good at tinkering and taking photos, but here it is.
Note: Look at all the youtube videos and you will not only learn how to, but learn a few lessons about foam.
1. Carefully remove the chrome trim. On the 72 there werre screws that were bent over? the Mike's seat had screws that weren't bent and easily reused, but ACE hardware should have what you need.
2. I cut about an inch from the top of the front and back as shown.
3. The blue foam is less dense . Iformed the bottom of the blue foam to fit into my cutouts.
4. Sprayed on the 3M, (follow directions), try to limit the over spray. I placed the blue foam on, continually pushing down and kneeding while it dried.
5. Then trimmed the blue foam with the electric carving knife to match the yellow.
6. I reused the clear plastic cover. On my old seat, the plastic disintegrated, but sandwich wrap would work toseal the water out.
7. Install seat cover. I bought a seat cover from ebay a long time ago, but it was the correct one for a 72. The earlier seats had a different shape from the 447's .

 

[Signal]

I was told to very carefully mould the cut foam with an 4" angle grinder.
It works really well but is messy, wear a face mask and you have to go very carefully as bad things will happen if the wheel bites a big chunk.
The end results was better than my carving knife attempts.

 

[willis]

100% WHAT SIGNAL SAYS ABOVE.

 

[AUTOMAN]

Try the place in Singapore.
They make seats for lot's of bikes.

I read they were up and above typical crap.

Funny how a block of PU foam is so expensive.

cliff

 

[Marlin72xs]

Signal: I had the wheel and the grinder out and said to myself, "This looks like trouble!" I stuck with the electric carving knife. Unless you're covering your seat with spandex, the foam dosn't have to be super smooth. The pic of the finished seat will appear soon.


There is now a dip in the seat that resembles the original 1972 design. It's a tad lower also like the original.