Maxim 550 Solo Seat Mod [pic heavy]

Here we go:

Remember the photoshop?
Before:


After:


And now the project!
Removed seat cover


Marked where to trim the foam


Trimmed!


Trimmed stock seat pan *** where the back of the pan rests on the small support (the one the inner fender attaches to) I will run short carriage bolts down from the pan into the frame to secure the new pan/cowl combo.


Chopped the rear


Traced profile onto posterboard from seat pan


Making "skeleton"


Added more "bones" to support plaster cloth


Used strips of masking tape to push/pull posterboard into desirable shape


Rigid Wrap plaster cloth! I haven't used this stuff since middle school art class!


Starting to cover


View from the back


Covered! Two layers so far.


So now all that's left to do for this step is to start covering it with Plaster of Paris. When it's dry I'll sand it smooth and trim the bottom into the shape I want. From that, I'll be able to make my fiberglass mold and fiberglass finished product. I'll keep you all updated with the progress.

 

k.joel.porter that back end will look very nice good work

 

very cool! is the seat becoming part of the new assembly or do you have some type of clip/retaining set up planned?

 

Thanks!

rustysavage, the short answer to your question is "yes." In other words, I haven't fully figured that out yet. I am definitely keeping the seat foam where it is and recovering it with that section from the original cover which is in fantastic shape. I'm leaning towards wrapping the cover around the foam and overlapping onto the plastic pan; overlapping the front as it was stock, and stapling to the sides about an inch and a half from the bottom of the foam. The only other thing I'm considering is shaving about a centimeter off the entire surface of the remaining foam. Of course this means the stock cover is going to need extensive alterations to make it fit. The advantage, however, is that it'll make the finished product look more streamlined. The new cowl, once it's formed from fiberglass will be epoxied to the pan.... I think...

 

That looks bada$$ already... keep us posted....

 

VERY NICE!! Working w/fiberglass from scratch like that is so cool... That's one fabricating skill I DON'T have. I'm always amazed at what guys can do with fiberglass. Looks like that is gonna be one sweet lookin' mod!!

 

Have you tried? I don't think it is that tough really. I mean, i know some guys who are all thumbs who have successfully done some fiberglass work.

 

Ooooh nice start, I'm liking this idea

 

k.j.p., after reading first post was hooked. A number of the replies you got sounded good to me. I've never worked with fiberglass myself. Man, YOU REALLY DONE GOOD!!! I'M IMPRESSED!!! :wink: ...

skillet

 

Nice look! I hate to be a buzz kill, but I hope you are thinking about somehow armoring the bottom. I hate to think of a rock going though all your beautiful work. Keep posting pics and doing what your imagination tells ya.

 

There no need to cover it with Plaster of Paris and make a mold.
Cover it with a Fiberglass Kit and use an Electric Sander to shape the Fiberglass.

Once you have the Shape you need "Finish" it with a coat of MarGlas Filler followed by critical forming and shaping of the MarGlas which cures rapidly ... then, a final skim coat of Bondo to hide imperfections and allow you to swand and prime a Finish that will be flawless.

 

Amazing suggestion, Rick! That'll definitely eliminate some steps and possibly a few headaches. The good news is that I haven't opened my 8lb tub of PoP... that's $9 back in my pocket towards fiberglass! I don't have an electric sander but I do have a pneumatic disc sander for my compressor. Will that be okay or will it be overkill? What's the best grit to use? I have 60 coarse and 150 fine discs.

 

60 Grit will cut the Fiberglass like butter.
You will be able to fashion the "Form" for laying-on MarGlas after cutting it with 60 Grit and Fine Tuning it with 80 or 120.

Once you've created the Foundation ...
Lay on the MarGlas
Just before the MarGlas hardens ... "Rough-shape it" with a "Cheese Grater type -- SureForm Tool.

"Work" the MarGlas down by cutting it with 180-220
As the work takes shape nicely ... 320
Hand sand it with 400 Dry
Fill low spots and cut wit 320.
Once you have it "Ready for people" with 400 Dry
Coat it with Primer
Sand the Primer with 400 or 600 Wet.
Have somebody look it over for Blems ... you won't see 'em.
Your mind doesn't let you see the imperfections.
Mark with Pencil
Fill or sand.
Re-Prime
600-Wet
800-Wet
Color
Let Color CURE for 48 Hours
1000-1200 Wet (Feel it getting smooth as a glass baby's ass)
Wash
Dry
Clear Coat 1

 

If I were you, I would go ahead with the mold idea.That way you would have something to work with later in case of damage.

 

bump.. Any updates on this?!?

 

lol... no. It's been sitting in my garage waiting for me to buy the fiberglass mat, resin, short strand, bondo, etc. The contracting business lightened up after I started the project so... you know... mortgage, utilities, & food took precedent...

The good news is I got a new marketing job that I start on the 15th so I'll be able to start back up soon and will certainly update!

 

Ok...so you've had a good solid 7 days on the new job....5 not counting weekends...so where's the update?!?!?!? lolol

 

I'm cringing when I say this... but... I'm thinking about scrubbing the project. Between night school, job, hour and a half commute, and the wife, I have no time to work on my project. And now it's riding season and I've lost my patience.

drag bars and forward controls are looking more appealing by the minute. It's not the look I want but whatever. Add another chopped 550 max to the list and get me back on the road.

 

Well, as long as you do something that is reversible to get you on the road you can always pick up where you left off when you have time. My chop/custom project sat for 3 years do to marrage and a child, but hey gotta do what ya gotta do.

 

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