Tiffany Haney
Bobber seats are lightweight and highly customisable, allowing riders to give their motorcycles a unique look. The process of covering a bobber seat pan involves several steps, including selecting the appropriate materials, crafting a template, shaping the seat pan, adding cushioning, and upholstering the final product. With careful planning and execution, riders can create a custom seat that suits their style and comfort preferences.
| Characteristics | Values |
|---|---|
| Materials | Steel, aluminium, sheet metal, polyurethane foam, leather, PU leather, vinyl |
| Steps | Measure and mark metal sheet, cut out shape, deburr edges, drill holes, bend metal, add tape, trace and cut foam, add adhesive, lay cushion, pull vinyl, rivet vinyl, trim vinyl, install bracket, mount seat |
| Cost | $5 for a plastic seat pan, $60-$300 for a fully-finished seat |
| Tools | Tape measure, permanent marker, work table, vice, duct tape, scissors or razor blade, craft spray adhesive, rivet gun, electric drill, sandpaper, metal file, electric nibbler, metal shears |
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What You'll Learn
Sketching and cutting out a paper template
To sketch and cut out a paper template for a bobber seat pan, start by selecting a sheet of paper that is large enough to accommodate the full size of your intended seat pan. Fold the sheet in half lengthwise. Sketch the basic design of your seat pan onto one side of the paper, including the desired dimensions and shape. If you're happy with the design, carefully cut the sketched portion out of the paper using scissors. Unfold the paper to use this as a template for your seat pan.
Once you have your paper template, lay it over a sheet of high-density foam and trace the template's outline onto the foam with a permanent marker. Cut the foam to shape using scissors or a razor blade—this will be the seat pan's cushion. Spray the top of the seat pan and the bottom of the foam cushion with a craft spray adhesive and let it set for about a minute before attaching the foam to the seat pan.
Now, lay your paper template over a sheet of 12-gauge metal and trace the outline with a permanent marker. Remove the template and use metal shears or an electric nibbler to cut out the shape. Deburr the edges of the freshly cut seat pan with a metal file and sandpaper to smooth out any rough or jagged edges.
Drill several holes along the perimeter of the metal seat pan using an electric drill with a 3/16-inch drill bit. Space the holes about half an inch from the edge and roughly 2 inches apart. These holes will be used to fasten the upholstery to the seat pan. Additionally, drill a pair of holes into the front of the seat pan using a 1/4-inch drill bit, with one hole 1 1/2 inches from the tip and the other 3 1/2 inches away.
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Bending the seat pan to the desired shape
Next, select a sheet of 12-gauge metal and place it on a work table. You can then create a template by folding a sheet of paper in half lengthwise and sketching your desired design. Cut out the template and lay it over the metal sheet. Trace the outline of the template onto the metal with a permanent marker.
After that, you can cut out the shape of your seat pan from the metal sheet using metal shears or an electric nibbler. Deburr the edges to remove any jagged portions and smooth them with a metal file and sandpaper. Now you're ready to start bending the metal to your desired shape. Place the seat pan into a vice and apply pressure to bend it. Most solo seats have a slight rise towards the rear and forward tips.
Finally, cover the edges of the seat pan with duct tape to prevent them from cutting through the upholstery. You can then lay your paper template over a sheet of high-density foam and trace the outline to create your cushion.
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Covering the seat pan's edge with duct tape
Covering the edges of a seat pan with duct tape is a crucial step in the process of creating a custom motorcycle seat. This technique not only ensures a smooth finish but also protects the seat's upholstery. Here's a detailed guide on how to cover the edges of a seat pan with duct tape:
Preparing the Seat Pan:
Before applying duct tape to the edges, it's essential to prepare the seat pan. Start by deburring the edges of the seat pan with a metal file and sandpaper. Remove any sharp or jagged edges to ensure a smooth surface for the duct tape to adhere to. Once the seat pan is smooth, it's time to drill the necessary holes for upholstery. Use an electric drill with a 3/16-inch drill bit to create holes along the perimeter, spaced about half an inch from the edge and 2 inches apart. These holes will be used later to fasten the upholstery securely.
Applying Duct Tape to the Edges:
- Obtain thin strips of duct tape: For this step, you'll need thin strips of duct tape, cut to an appropriate length to cover the edges. The strips should be long enough to lay over the top of the seat pan and bend around to the bottom.
- Cover the edges: Lay the duct tape strips over the top of the seat pan, then carefully bend them around the edges. Press the tape onto the bottom of the pan, ensuring a secure hold. Continue this process until you have covered the entire edge of the pan.
- Create a slightly rounded profile: As you work your way around the seat pan, aim for a slightly rounded profile along the edges. This helps prevent the sharp edge of the seat pan from cutting through the upholstery material later.
- Overlap duct tape strips: When applying duct tape strips, there are different approaches to overlapping. For a unique ""duct tape look and feel,"" you can apply the strips in a clockwise direction, barely overlapping on the outside edge and significantly overlapping on the inside. Alternatively, aim for minimal overlap on the outside edge to maintain a smooth surface.
- Smoothen the edges: If the ripped side of the duct tape is exposed due to overlapping, you may need to apply super glue to the edges to create a smooth surface. The higher the edges stick up, the more coats of finish you'll need to apply.
Finishing Touches:
Once the duct tape application is complete, you can proceed with the next steps in seat pan creation. This typically includes adding a layer of high-density foam for cushioning and using craft spray adhesive to attach the foam to the seat pan. After that, you can lay vinyl over the foam, pulling it tightly and riveting it in place. Finally, trim away any excess vinyl, and your custom motorcycle seat will be ready for installation!
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Creating the seat pan's cushion
The first step in creating the seat pan's cushion is to select a sheet of high-density foam. The foam will provide comfort and support for the rider, so it is important to choose a high-quality foam that is durable and can withstand the weight of the rider.
Next, you will need to create a template for the shape of your cushion. Start by selecting a sheet of paper that is large enough to accommodate the full size of your intended cushion. Fold the sheet in half lengthwise and sketch the basic design of your cushion onto one side of the paper. If you are happy with the design, cut the sketched portion out of the paper using scissors. This will give you a symmetrical template that you can use to trace the shape of your cushion onto the foam.
Once you have created your template, lay it over the sheet of high-density foam and trace the outline of the template onto the foam using a permanent marker. Carefully cut the shape of the cushion out of the foam using scissors or a razor blade. It is important to cut the foam accurately to ensure a snug fit with the seat pan.
Before attaching the cushion to the seat pan, it is important to round the edges of the pan to prevent the sharp metal edges from cutting through the upholstery. To do this, cover the edges of the seat pan with thin strips of duct tape, pressing the tape firmly onto the top and bottom of the pan.
Now it's time to attach the cushion to the seat pan. Spray the top of the seat pan and the bottom of the foam cushion with a craft spray adhesive. Allow the adhesive to set for about a minute, and then carefully lay the cushion onto the seat pan, pressing it firmly into place.
Finally, you will need to cover the foam cushion with a durable material such as vinyl, leather, or PU leather. Spray the top of the foam cushion with the craft adhesive and lay the vinyl over it, pulling it tightly around the foam and the pan. Secure the vinyl in place using rivets and a rivet gun, and then trim away any excess material with scissors.
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Riveting vinyl to the seat pan
To begin the process of riveting vinyl to a seat pan, you must first ensure that you have a seat pan with holes drilled for rivets. The next step is to cover the seat pan with foam and shape it accordingly. Then, cover the foam with your desired material, such as vinyl. Pull the vinyl tightly over the foam and the pan, and use a rivet gun to rivet the vinyl in place through the pre-drilled holes. It is recommended to use washers with the rivets to prevent the material from pulling through. This method of riveting vinyl to a seat pan is a basic and straightforward approach, and there may be alternative techniques available.
When creating a custom seat for a motorcycle, it is essential to consider the design and shape of the seat pan. You can start by sketching the basic design of your desired seat pan onto a folded sheet of paper. Once you are satisfied with the design, cut out the sketched portion to create a template. This template will be used to trace the shape onto the sheet metal, which can then be cut out using metal shears or an electric nibbler. It is important to deburr the edges of the freshly cut seat pan to ensure there are no sharp edges.
Drilling holes in the seat pan is a crucial step to facilitate the riveting process. It is recommended to drill several holes along the perimeter of the seat pan, spaced about half an inch from the edge and approximately 2 inches apart. These holes will be used to fasten the upholstery securely. Additionally, drilling a pair of holes in the front of the seat pan will help with the mounting process. The holes should be aligned along the forward tip, with the first hole positioned approximately 1.5 inches from the tip and the second hole 3.5 inches away.
After the holes have been drilled, the seat pan should be covered with foam to provide cushioning. High-density foam is a suitable option, and you can trace the template's outline onto the foam before cutting out the shape. A craft spray adhesive can be applied to both the top of the seat pan and the bottom of the foam cushion to ensure a secure bond. Once the adhesive has set for about a minute, carefully place the cushion onto the seat pan.
With the foam in place, you can begin the process of riveting the vinyl to the seat pan. Spray the top of the foam with the adhesive and lay the vinyl over it, pulling it tightly to ensure a smooth surface. Starting at the front of the seat pan, use a rivet gun to press rivets through the vinyl and into the pre-drilled holes in the seat pan. Continue this process until the entire seat is covered tightly with the vinyl sheet. Finally, trim away any excess vinyl using scissors for a neat finish.
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Frequently asked questions
The first step is to select a sheet of 12-gauge metal and create a template for your desired seat pan shape. Trace the template onto the metal sheet and cut out the shape using appropriate tools.
After cutting out your metal seat pan, deburr the edges to smooth out any rough or jagged areas. Drill holes along the perimeter for fastening the upholstery. Cover the edges with duct tape to prevent cutting through the upholstery material.
High-density foam is recommended for the seat pan's cushion. Trace your template onto the foam and cut out the shape. Spray both the foam and the seat pan with a craft adhesive and let it set before attaching the foam cushion.
You can use various materials such as leather, PU leather, or vinyl to cover your bobber seat pan. Pull the material tightly around the foam and pan, and secure it using rivets and a rivet gun. Trim away any excess material for a neat finish.
