Expanding foam seat…. Done!

2025-04-26T22:26:18Z

I’ve had this kit for a couple of years but have been a little scared of attempting it, probably in part due to reading the infamous ‘canoe’ tale about what can happen if you get it wrong!

Anyhow, having recently done my headrest, I wanted to sort the seat ahead of our Cornwall trip in a few weeks so that I’m a bit more comfortable for longer stretches.

I had to complete the task on my own as Mrs Stu is not feeling too good currently, so made plenty of preparations to ensure that if things did go wrong, the car wouldn’t get covered in the stuff. As it turned out, it was all a bit of an anti climax and it went very well.

I used a very large, thick plastic bag which was an option with the foam kit. I wanted a bit of padding under my bum, so put some foam on a very thin piece of ply to act as a base, then popped this in the bag. I cut some cardboard to shape and put this down the sides in an attempt to prevent it locking in to place again the chassis rails which as you will see only partially worked.

I had a couple of plastic measuring jugs and bought some cheap buckets specially for the job, and mixed up 600ml of each part first off. Once poured in, I sat myself down on the bag and wriggled around until comfortable. It got fairly warm, but nothing too bad, and I was a bit surprised that the first pouring just reached the back of my bum, so more was needed.

After about 15 mins it seemed firm enough for me to get out and mix the remainder of the kit and have another go. This time it filled the space behind me ok, and worked its way right up to above shoulder level.

Once out, I left it to set whilst having dinner, then set to work trying to get the b****r out! The cardboard had bent outwards allowing the foam to spread into the frame a little so I had to carefully cut the sides off and free the seat.

The back section proved a little fragile, so I cut off the top down to a more useable level, having to glue sections back on which had broken away. Then a fair amount of shaping with a knife, and I also cut the hole for the harness to pass through.

Finally, I covered it liberally with the tape I bought as part of the kit, and Bob’s your uncle, a foam seat which is actually remarkably comfortable, even if it’s not very beautiful!