Foam Injections - anyone ever seen it done?

The newer 1982 Fairmont reclining bucket seats are nice. They feel like the famous Recaro seats. I had them all apart, cleaned off the fabric and I know that I have to re-upholster them sometime next Spring. But like any foam, after 25 years, it starts to turn to dust.

I can tell the way they're made that they were done in a mold, with blown in injection products. Maybe with some modest heat (under 200F). Has anyone seen any soft foam offered in rattle cans or 2-part mixes?

It's fairly easy to make a two-part mold for bucket seat bottoms. So making a new pair (the same top half of the seat cushion, but different bottom half of the seat cushion for armrest and recliner hardware) would be done with Paris Plaster or papier mache. Band them together with bungie cords and blow in the new foam mix, then let it gel. That's my crude theory, anyway.

 

I don't know how they do it. but I have seen upholstery work done on discovery channel and they just buy square foam and use a electric knife to trim them to the shape they need.

 

Never thought about that either. We've got some Discovery Channel Video tapes. So the Library will too. We just got a new eLibrary service where a member can view/read online. Good idea! Thanks.

 

check out American Hot Rod but don't pay attention to Boyd Coddington. He uses a upholstery shop and they show how they do it.

 

yup...the Christmas turkey concept is all ive ever done

just carve the piece till desired effect...and insert!

 

What's a good foam density? I've done that on home furniture, but automotive is denser, right?

 

in my world ...its most commonly referred to as 'RV' foam
but as for the technical term...i dinno

 

We used to buy a quality called Royal Jelly, at about 2 lbs/per sq. in. for seat cushions, after working these seats, my guess is 5 lbs. but I'll check and post my findings for future reference.

 

Stormin' See if you can get Hi density foam it will hold up better.

 

Ok, Here's a comment about foam density scams to consumers:
http://searchwarp.com/swa148386.htm

Here's a pretty decent explanation of foam properties. It's a bedding site:
http://www.simplepedic.com/foam-quality.html

Here's a Foam trade association's explanation:
http://www.pfa.org/jifsg/jifsgs1.html

Now, let's get down to real world info. My 1987 Volks Cabriolet has firm seats, that hugged my butt too tight, and was harsh on the shoulders. I used it for City scooting, not Highway or long drives. It was great for holding you in tight turns or one-wheel donuts, but it's not a real comfy driving seat. I'd put it at Super High Density. You could use that foam to excersise your hand and wrist muscles.

The Riviera had nice seats, but they're made for heavy to medium weight guys. I'm 165 pounds. So over a seat surface of 4 sq. ft. (approx.) that's 42 lbs per sq. foot. Most cars are made for folks from light-weight women of 110 lbs to 6 footers coming in at 250 pounds. So the industry average would be about 63 pounds per sq ft. of weight MAX. Assuming that thickness only relates to what these two sites call IFD or ILD (indentation load deflection), not 'bounce to the ounce' , I'd be looking for a FIRM ILD (32-40) and for a 6" high foam cushion, something around the 3 Density rating (3 lbs per cubic ft.).

I don't want to end up buying some 2" thick cushion afterwards, so that I can see over the steering wheel.

What ya think?

 

I like soft and comfy myself.

 

I just got a brainwave! After you slice and dice it, you've got all those open cells that will fill up with dust, gasses (from the nether regions ), and any beverage you spill, plus the friction between the fabric and the foam.

If this foam is a Latex foam, it won't likely be UV treated, but the Polyurethane would. It might be a simple thing to get some heat-shrink bags or wrap, form a bag over the finished (shaped) foam, and use a haridryer and vacuum to wrap it tightly to protect the surface. It wouldn't matter if you're opening it up with hog-ring holes underneath, but the surface would be shaped and secure and any junk and muck would roll off onto the floor.

 

There are no gasses in my wagon....

 

Never mix milk or ice cream after eating hot chile or a mexican salsa on pork tortillas. It won't be just gasses.

 

Yup, take it to Gabe's. he knows how to do interior work.