Making seat foams

[chuck hahn]

I guess this fits the general category. Ive been looking at the 2 part foam chemical kits as im interested in making a mold for the 1000 stepped seat and tryingbto pour a seat foam. Some time someone posted a link to a repo foam but they didnt ship to USA. Ive looked and cat find that link now.
So is this kit the right kind of foam seats are made from??? Im assuming polyurethane is the correct type.

6 Lb. Density Expanding Pour Foam, 2 Part Polyurethane Closed Cell Liquid Foa... | eBay​

 

[Don R]

I'd think that will cure hard, it might be good for the mold, but I don't know what the seat foam is made of. I'd be more inclined to sculpt it from layers of different densities of upholstery foam. I cut down a large double bucket seat into a shape that fit a stock cover. I used an electric knife and a 4 1/2" grinder with an 80 grit sanding disc.

 

[chuck hahn]

Don. my idea is to make a form from my original foam for stock accuracy. If i can get the right kit just mix and pour and none of the other nonsense is needed. I can make a pan mold and pour that. Then all thats needed is to slice each half to the correct foam height and marry them together.

 

[danny01975]

I'd be more inclined to sculpt it from layers of different densities of upholstery foam. I cut down a large double bucket seat into a shape that fit a stock cover. I used an electric knife and a 4 1/2" grinder with an 80 grit sanding disc.

This is the way. I've been looking at re-making a factory GK seat since they're so hard to find. I have a friend who is an upholsterer who want to sew the cover for me. He, and all of the videos I've watched say to do this same thing. Start with a big block of foam, or layers of varying density foam, then carve it down using an electric knife.

Then you try to fit the cover. Then carve some more. Check the fit. Etc.. Repeat until it fits.

But if you do end up making some kind of mold that works, do let me know! That sure would be easier.

 

[chuck hahn]

Danny, making a mold is no problem. Knowing which soup to pour into it is what i have no knowledge of. IF i can get conclusive info on that im good

 

[Nessism]

This is the way. I've been looking at re-making a factory GK seat since they're so hard to find. I have a friend who is an upholsterer who want to sew the cover for me. He, and all of the videos I've watched say to do this same thing. Start with a big block of foam, or layers of varying density foam, then carve it down using an electric knife.

Then you try to fit the cover. Then carve some more. Check the fit. Etc.. Repeat until it fits.

But if you do end up making some kind of mold that works, do let me know! That sure would be easier.

I used to work at a place that made, among other products, aircraft crew seats. All the cushions were made from shaved foam, various densities, glued together, just like you mention. If building a new seat, that's how I'd go about it. Getting the contour to the pan just right wouldn't be easy, though. chuck's expanding foam trick would make that easier, but if doing that, I'd cut it down low and just use it for the base.

 

[chuck hahn]

I am gonna take the stock foam to a shop not too far away and see what they charge to copy it.

 

[Don R]

I'm just not aware of an open cell or closed cell foam that you can pour that acts like seat foam. Most of it sets hard.

 

[chuck hahn]

Seat foam is made from some sauce and poured. I just need to find out what that is and im good to go.

 

[Rich82GS750TZ]

Google is your friend. This took 3 seconds. Try words like “poured foam to form a motorcycle seat”

Just one of many results:

 

[Grimly]

Google is your friend. This took 3 seconds. Try words like “poured foam to form a motorcycle seat”

Just one of many results:

Interesting. However, dirt bikes aren't known for their seat comfort on long distances.

 

[Rich82GS750TZ]

Point is, yes, a squishable foam can, and is possible from a poured-in-mold process to make a motorcycle seat. This is the process I believe Chuck has in mind as a alternative to the typical build-up-layers-of-varying-density-foams-then-cut/shave-to-shape process. Obviously, more research is needed on his part to find out if it’s even something that should be considered for a street bike seat, and if so, what would be the best recipe to use.

 

[chuck hahn]

Its easy IF you have a slight clue of what to google.. ha ha.

 

[Don R]

Awesome I'll be watching along to see how it goes.

 

[chuck hahn]

That pourable mix as in the video is exactly what i was thinking about. Take my stock foam and do a layered fiberglass mold on it. Do the same on the pan so the recesses also get formed in the pour. Separate mold halves and clean up seam runout just like he did in the video. If it works then i have a mold for making them on request for members.

 

[Nessism]

Why not use the pan as the top section of the mold?

 

[chuck hahn]

Ed. I only have the one pan for the seat on the current ongoing skunk project. So if i had a spare pan that would work with the release agent and all id have to mold is the surface of the seat itself. As it looks now the easiest thing to do is make the fiberglass mold of the pan and clamp the two together like he did in the video.

 

[chuck hahn]

If anyone has an old seat pan they would donate to the experiment ill gladly accept.

 

[Don R]

I read that saran wrap makes a suitable wrapper for the part to be molded into a form. Painters wrap is self adhesive and strips of that might work also, there's a pourable foam that is used to make molds for injection molding parts, the guy at FB-stuff.com makes Honda sidecovers that way. He got a good pair of 76 Super Sport sidecovers to make a mold from on a friday, and monday morning he had them for sale. It's a part time gig or he would likely be making them for everything.

 

[chuck hahn]

Yes plastic wrap or green tape to cover the part being molded. WD40 as the release agent then start laying on the fiberglass. Ill make a top foam mold and a pan mold. Marry them and pour. Mind you this is gonna be an ongoing venture but i will post pics at some point.