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  #16 (permalink)  
Old 03-26-2009, 09:24 AM
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Hi Dan
seeing as this thread will be seen by others doing the same thing I want to point out a mistake I have made already.

When I allowed 18 inches on the seat base for a comfortable seating area I neglected to allow for the two inches of foam on the seat back that effectively pushes the seated person forward at least two inches (more if you want a lumbar support). So now my seat is two inches too shallow and also the square cut-outs are too close to the back edge and only allow me two inches to apply foam and webbing. I am still trying to work around it but could end up starting again on the base. It might be a good idea to point this out at the beginning of the thread so other beginners like myself don't make the same mistake.

I am hoping I can make up the shortfall at the front by angling the front edge of the cushion back down to the base, and do you think 1 inch of foam on the back would be sufficient with maybe some extra thickness on the edges, lumbar and top to give it some shape. Part of my problem is if I extend the front of the seat another two inches I might have difficulty getting my feet into the car because it will narrow the gap between the front of the seat and the door opening.

Last edited by scrimshaw; 03-26-2009 at 09:33 AM.
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  #17 (permalink)  
Old 03-26-2009, 09:28 AM
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If you haven't done the seat back yet, just make it a few inches longer top to bottom and butt the seat bottom up to it.
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Old 03-30-2009, 08:22 AM
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Some pics of what I have done so far.

I am still waiting on the elasbelt. Managed to scrounge the foam for free, at least I won't be mad if I screw it up on the first try cutting it out. Any tips on the best tool to use?
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Old 03-30-2009, 08:39 AM
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If you don't have a foam saw (which you probably don't) go to Wally World and get yourself a Hamilton-Beach electric carving knife (about $20.) They cut foam great until the blade gets dull (a few years with occasional use.) Then it's up to you whether or not to have the blade sharpened or get a new knife.

I have also discovered that a band saw with a very fine blade will also cut thick foam with little problem. Closed cell foam cuts easier than open cell foam, but if you have a 2" or thicker piece of open cell foam you need to trim down, get a fine toothed blade for your band saw, tune it up, and spray some silicone lube on the blade as it's running. Cutting through thick foam is like slicing through hot butter this way.

WARNING: If you've used the band saw or blade on wood or metal, clean up the saw and use a new blade. Failure to do so will mean you'll have wood or metal particles in your foam - some of them quite large. DO NOT try to cut foam with any other kind of power saw. Forget the table saw, radial arm saw, and even the jigsaw. They don't cut through the foam fast enough, and you'll wind up with a potentially dangerous situation on your hands.
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Old 03-30-2009, 08:57 AM
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Quote:
Originally Posted by scrimshaw
Some pics of what I have done so far.

I am still waiting on the elasbelt. Managed to scrounge the foam for free, at least I won't be mad if I screw it up on the first try cutting it out. Any tips on the best tool to use?
Looks good so far! what kinda car is that? that looks pretty cool too!

I am looking forward to seeing the finished product of both.

all the best

~J
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Old 03-30-2009, 10:05 AM
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If they still make electric carving knives. Otherwise I would go to Wal-Mart and buy an electric fish fillet knife which would be more heavy duty. They are about $35. The best tool for the job is a 12" Bosch 1575 foam saw, but I doubt you'd want to spend $275 to $400 for one. You've done a really nice job so far.
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Old 03-30-2009, 03:41 PM
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Quote:
Originally Posted by DanTwoLakes
If they still make electric carving knives. Otherwise I would go to Wal-Mart and buy an electric fish fillet knife which would be more heavy duty. They are about $35. The best tool for the job is a 12" Bosch 1575 foam saw, but I doubt you'd want to spend $275 to $400 for one. You've done a really nice job so far.
Gotta tell ya, Dan, the electric carving knife I got last year is virtually identical to the knife in your pic - except it is all white and $15 cheaper. Yeah, they still make 'em. They're made by Hamilton-Beach, and they're in the kitchen department.

I'm still saving up for a pneumatic foam saw - those things are very pricy.
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Old 03-30-2009, 07:15 PM
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The electric fisherman is made in Louisiana by the Mister Twister company. It is heavier duty, has better blades, and has a very good warranty.
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Old 03-31-2009, 09:59 AM
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Dan

You asked in an earlier post 'how am I going to make the seat?'

Well the short answer would be 'however you suggest I make it'. But I really have no idea at this point of the details and as I said I am a real beginner, I don't even know what 'sew foam' is so maybe I should do a bit of reading on the basics of upholstery. Is there a thread that you can recommend?
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Old 03-31-2009, 12:26 PM
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Quote:
Originally Posted by scrimshaw
Dan

You asked in an earlier post 'how am I going to make the seat?'

Well the short answer would be 'however you suggest I make it'. But I really have no idea at this point of the details and as I said I am a real beginner, I don't even know what 'sew foam' is so maybe I should do a bit of reading on the basics of upholstery. Is there a thread that you can recommend?
Read this thread through about 4 times: CLICK HERE
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