I wrapped up the seat pan fabrication recently so it was time to start shaping the foam. Here are some process shots. Unfortunately I don’t have specs on the foam type. I bought it years ago in a big roll from a local upholsterer. It’s a med/firm density. I use 3M High Strength 90 spray adhesive to bond the foam to the pan and itself. The rough shaping I do by electric carving knife. You’ll want one that’s 130 watts or more. I’ve burnt out a few 100W knives. The refined contouring I do with an angle grinder and flap wheel. Upholstery glue only sticks to powder coat and raw metal so if your pan is mild steel get it powdered before sticking the foam down. Otherwise the pan will rust once the foam takes on moisture.
I measure and draw out a center line and cross lines to help keep things symmetric. After those are chopped off I'll lay down contour lines to follow with the flap wheel.
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