THE BACKSame procedure as base - Measure the back and cut the rectangle out of plywood; I used the rest the 3/4" sheet that the base was cut out of.
One could lay the seat back spring frame onto the plywood rectangle to trace the corner cuts. I probably should have but did not as I got carried away by cutting the clips out of the frame with a cutoff wheel. On the plus side, this gave me the seat spring frame ends including the corners in a more use able size, granted they are in two pieces.
Passenger Side of seat back after the cutting wheelCenter of seat back after the cutting wheelDriver Side of seat back after the cutting wheelSorry no pictures of cutting the round corner but here are the two pieces of the seat back spring frame that I used to trace the corners onto the seat.
SAVE THESES for making your seat back I should have used the
finished edge as a bottom of the seat back as a factory square edge will make the next step easier -- that step being the installation of the clips.
The top and bottom clips are located directly above and below each other. Thus, a factory square edge would allow a t-square to draw lines that would guarantee they line up with far more confidence.
Drawing the linesUnfortunately I did not take any shots of how I marked where the seat back clips go. It was hot in the garage that day even with a fan! So I will try to describe what I did:
1. Do a dry run of the the plywood seat back after the corners are rounded making sure the top corners matched the curvature of the seat frame. The plywood seat back should be sitting a bit low as it is resting on the ledge of the seat frame.
2. Lay the plywood seat back forward so it is sitting on the edge of the seat frame (were the bottom clips are inserted) forward over the previously made seat plywood base. This exposes the holes in the frame's ledge which the bottom clips side into -- makes marking the location easier.
3. Square up the plywood seat back in the opening of the seat frame. Lots of measurements knowing I had to hit the mark!
4. Marked the plywood denoting each side of the seat frame's cut out for the bottom clips.
5. Used a drywall t-square and extended the marks the full height of the seat back.
The seat back once the clips are mounted. Location of the clipsI took some pictures before I cut the clips off the spring frame. This will help locate the clips after I cut and ground the seat ribs off the clips. (I will insert a picture of the clips after the grinding and cutting)
Clip location showing why you need some space on the seat back to upholster the seat The vinyl will need to bunch up behind the clip
Clip location on a bare frame I believe I will have to notch the plywood to provide room for the vinyl to bunch up. Perhaps running a router to give room for the vinyl to be bunched up during re-upholstering .
AVOID a possible "oh [censored]" as they wipe out 1000 atta-boys1. Mount the top clips
First. I used 1/2-20 bolts and a large washer.
2. Once the top clips are mounted, hang the back in place and center the gabs.
3. Make sure the bottom still lines up - it should! Mark any adjustments needed.
4. Trace the top of the ledge (which the bottom clip slides into) onto the back of the plywood. The mounting bolts for the bottom clips MUST be above this line for the seat back to fit properly. I did not and I have to round out the mounting holes for one clip so the bolt is above this line
5. Take seat back out, drill holes and bolt in the clips.
The seat back once the clips are mounted. The seat back in frame The seat back in frame The seat back in frame The seat back in frame The seat back in frame from the back What is next:
1. Take the clips off take a few pictures and paint them.
2. Order the foam (why did I wait?)
3. mount the foam.
4. shape the foam.
5. Drive around testing the shape for fit and comfort.
6. Go back to #4 until the foam fits me into the truck.
Unfortunately, I go to loose some gut or shorten the steering wheel or .....
<to be Continued>
