Tiffany Haney
Fiberglass seat pans are a popular DIY project for motorcycle enthusiasts, who often opt to create custom seat pans to replace stock or bolt-on parts. The flexibility of a fiberglass seat pan depends on the number of layers of fiberglass matting or cloth used in its construction, with more layers resulting in less flexibility. For example, one DIYer reported that their seat pan, which had six layers of matting between layers of cloth, had a little flex but not a ton. Another user commented that woven fiberglass is more flexible than chop strand matting, requiring more layers to achieve similar rigidity. When creating a fiberglass seat pan, it is important to consider the desired shape, the method of attachment to the motorcycle frame, and the need for reinforcement in areas where drilling or mounting will occur to prevent cracking.
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What You'll Learn
The number of layers of glass used
One source recommends using a layer of 4 oz cloth and 2:1 epoxy resin for reinforcement and crack repair. Another suggests using a few layers of mat sandwiched between layers of cloth for added strength. This technique is supported by another source, who also recommends using a woven cloth for added strength.
The number of layers of glass can also depend on the shape of the seat pan. More complex shapes may require additional layers of glass to achieve the desired strength and flexibility. It is recommended to keep the shape simple and smooth, as abstract shapes can make it difficult to create a flawless cushion.
Additionally, the type of glass fibre used can impact the number of layers required. For example, carbon fibre is known for its strength and lightweight properties, requiring less material to achieve the same strength as other types of glass fibre.
Overall, the number of layers of glass used in a fibreglass seat pan can vary depending on the specific requirements and constraints of the project. It is important to consider the desired strength, flexibility, and shape when determining the number of layers needed.
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The type of glass used
Fiberglass is a versatile material with numerous applications, including the creation of seat pans. Its flexibility and mouldability are among its most appealing features, allowing it to be shaped into various forms, including rods, window reinforcements, tree stakes, and more.
When it comes to the type of glass used in fiberglass, there are several options, each with distinct advantages and disadvantages. Here is an overview of some common types of glass used in fiberglass:
E-Glass (Electrical Glass)
E-glass is the most common type of fiberglass, known for its strength, durability, and resistance to rust and corrosion. It is made from a blend of silica sand, calcium carbonate, and other minerals. E-glass exhibits excellent electrical and thermal insulation properties, making it ideal for electronics and heat insulation. It is widely used in boat hulls, surfboards, and home insulation.
S-Glass (Structural Glass)
S-glass is stronger and more resistant to wear and tear than E-glass. It is composed of silica sand and alumina, resulting in exceptional strength and flexibility. This type of glass is commonly used in applications requiring high performance, such as aerospace components, sporting goods, wind turbine blades, and industrial and commercial applications.
A-Glass (Alkali-Lime Glass)
A-glass is the most commonly used type for insulation due to its high thermal resistance and low weight. It is made from alumino-borosilicate glass and is often employed in thermal insulation for homes and buildings, as well as boat hulls and other products.
C-Glass (Chemical Glass)
C-glass is the most expensive type of fiberglass, offering high strength and heat resistance. It is made from calcium-magnesium-silicate glass and is commonly used in high-performance applications, including aerospace, automotive, and sporting goods.
D-Glass
D-glass is known for its strength and flexibility, making it suitable for aerospace components, sporting goods, and electrical insulation. It is composed of silica sand, boron oxide, and aluminium oxide.
AR-Glass
AR-glass is made from strands of aramid fibres and is used in various applications.
Each type of glass fibre has unique characteristics, and the choice depends on the specific requirements of the application. The flexibility of the final product will also depend on the manufacturing process and the way the fibres are oriented during production.
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The shape of the seat pan
The first step is to determine the desired shape of the seat pan and how it will fit onto the sub-frame or frame rails of the bike. It is important to ensure that there will be enough seat pan left for back support after adding foam to the bottom. The shape of the backrest can be trimmed to personal preference, but it should generally be high enough to provide adequate back support.
When shaping the seat pan, it is advisable to avoid complex or abstract shapes, as they can make it difficult to create a flawless cushion. Simple shapes, such as smooth curves or points, are easier to work with and are less likely to result in imperfections.
The next step is to mark the centre of the seat pan at the front and rear and begin trimming to achieve the desired shape. An air saw, band saw, or cut-off wheel can be used for this process. It is important to trim and reinstall the seat pan several times to ensure a precise fit. Symmetry is also crucial, as it ensures that the seat pan aligns correctly with the bike's frame.
After trimming, the edges of the seat pan should be sanded smooth and straight. This step ensures that the seat pan aligns properly with the bike's frame and tank style and can be easily fixed and removed. Additionally, sanding creates a smooth surface for the application of foam or upholstery.
When shaping the seat pan, it is also essential to consider the method of mounting the seat to the bike. Different bikes may require different mounting methods, such as bolts, suction cups, or welding tabs to the frame. These considerations will impact the final shape and design of the seat pan.
Overall, the shape of the seat pan is a critical aspect of creating a custom fibreglass seat pan. By keeping the design simple, symmetrical, and smooth, one can achieve a well-fitting and aesthetically pleasing result.
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The method of attachment to the frame
When it comes to attaching a fibreglass seat pan to the frame, there are several methods that can be employed, depending on the specific requirements and constraints of your project. Here are some detailed instructions and considerations for the method of attachment:
Planning and Preparation:
Before beginning the attachment process, it is crucial to plan and prepare. Determine the shape of your seat pan and how it will sit on the frame. Consider the type of bike you are working with, as different bikes may require unique approaches to mounting the seat. Decide on the mounting method, such as using bolts, nuts, washers, or hinges, and gather the necessary materials and tools.
Mounting Techniques:
One common method of attaching a fibreglass seat pan to the frame is by utilising bolts and nuts. You can weld tabs onto the frame rails and attach bolts to a flat bar that matches the tabs. This provides a secure connection between the seat pan and the frame. If welding is not an option, you can also drill holes and use lock nuts and threads to secure the bolts. Consider using through bolts with penny washers for added strength and security. Additionally, reinforce any areas where you drill through with washers and an extra fibreglass patch to prevent cracking.
Fastening with Hardware:
Another approach is to incorporate hardware such as nuts and bolts directly into the fibreglass seat pan. This can be achieved by embedding Tee nuts or bolts glassed into the pan during the fibreglassing process. This method ensures a sturdy connection between the seat pan and the frame without the need for drilling or welding onto the frame itself.
Suction Cups:
For certain applications, suction cups can be used to attach the seat pan to the rear of the frame. Ensure that the area where the suction cup makes contact is smooth, free from holes or dents, and adequately curved to facilitate a strong suction hold.
Hinge Setup:
If you require easy access to the seat pan or underlying components, consider implementing a hinge setup. This method allows for convenient removal and replacement of the seat pan without the need for complex fastening mechanisms.
Final Thoughts:
Regardless of the chosen attachment method, it is essential to prioritise safety and stability. Test the security of the attachment method by applying pressure or weight to the seat pan to ensure it can withstand expected loads. Always follow manufacturer guidelines and instructions for any materials or hardware used in the attachment process.
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The tools required
The tools and materials required to make a fibreglass seat pan include:
- 24 oz. polyester fibreglass resin and hardener
- 2 yards 3/4 oz. fibreglass mat
- 1/2 yard fibreglass roving or cloth
- Cheap 2" brushes
- Mold release wax, car wax, parting wax, bowling alley wax, or WD40
- 3M paint tape
- Aluminium A/C duct tape
- Cardboard
- Rubber gloves
- Heavy-duty gloves
- Face mask and eye protection
- Plastic or boat mask
- Mixing cup and stick
- Tools for trimming the pan, such as an air saw, band saw, or cut-off wheel
- Blue tape
- Suction cup
- Tongue or bolts
- Epoxy
- Steel straps
- Nuts
- Washers
- Sandpaper
It is important to work in a well-ventilated area and in the shade when creating a fibreglass seat pan. It is also crucial to take your time and wear the appropriate protective gear, such as gloves, a face mask, and eye protection.
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Frequently asked questions
Making a fibreglass seat pan is a complex process that requires a lot of safety measures and specific tools. You will need to decide on the shape of your seat pan and how it will sit on your sub-frame. You will then need to reinforce the seat pan with washers and an extra fibreglass patch to prevent cracking. You can use cardboard cutouts to help you decide on the shape. You will then need to trim the backrest area and add foam for back support. Finally, you will need to figure out how to mount the seat to the sub-frame.
You will need thick gloves, heavy-duty gloves, a face mask, eye protection, a mixing cup and stick, tools for trimming, mould release wax, car wax or bowling alley wax, a couple of cheap 2" brushes, 24 oz. polyester fibreglass resin and hardener, 2 yards 3/4 oz. fibreglass mat, 1/2 yard fibreglass roving or cloth, and aluminium a/c duct tape.
The flexibility of a fibreglass seat pan depends on the number of layers of fibreglass mat and cloth used. The more layers, the less flexible the seat pan will be. However, woven fibreglass is more flexible than chop strand matting and needs more layers.
