'wittle 'wesistor (Mini Jeep)

[Functional Artist]

Foam Test
I've made many kart seats using Wal-Mart "seat foam"
...but, I've also, noticed that it doesn't seem to actually provide much support
...& most times (when sitting/riding) you can still feel the wooden platform, under the foam

Automotive seat foam seems denser or seems ta provide better "butt support"

So, I did a quick test using ~2" of each kind of foam
Left - Wall-mart foam
Right - Automotive seat foam

I added a 1" x 3" x 3" steel weight to each sample
...& both samples seemed to support the weight pretty well

Then, I added another steel weight, to each sample

The Wal-mart foam quickly "failed"
...but, the Automotive foam still supported the additional weight, pretty well

* Not really scientific or nuthin'
...just a quick "backyard" test or demonstration of the (2) different kind of seat foams

 

[BaconBitRacing]

I think this classifies as "Weird Science"

But very useful science

 

[Functional Artist]

Workin' on the seats

After figurin' placment, I trimmed the foam down to the same size as the plywood base

Then, I trimmed the upholstery around the perimeter of the "base", leaving 3"-4" for the wrap around
...& marked & cut the center, of the "corners"

Then, trimmed the corners a bit more

Folded 'er inside out
...& then, pinched the (2) pieces together, for sewing

A couple of "clips" help holdin' 'er together

Use real upholstery thread (if you want it to last for a while)

Had ta take a break, for a surprise inspection, before sewing them corners up

After sewing the corners up, it should, kinda look like an inverted bowl

 

[ezcome-ezgo]

You can see the density of the "air pockets" in the foam. That's a good indicator of the "support" it can provide. I am enjoying this journey with you.

 

[Functional Artist]

After sewing, turn the piece so the inside, is back on the inside

Fold the edges of the upholstery under (for a nice clean look)
...& hold 'er in place for staplin'

...& then, starta staplin' (just a couple, on each side, at first)

Till, itsa all stapled down good (all of the way around)

I also, tacked the corners for a little additional support, on them DIY seams

The first seat bottom turned out like this

Not perfect
...but, not bad

It's pretty straight
...& I was able to keep/maintain the "groove pattern"

 

[Functional Artist]

The second seat bottom, seemed to turn out a little bit better than, the first one (practice)

...but, they are kinda/pretty close

Another view (they are ~3" tall)

* The bottom of the upholstery on the right seat bottom is not crooked
...it's the camera angle
...ya, it's the camera angle

 

[G.W]

Looks comfy

 

[Functional Artist]

The seat backs were a bit more challenging

This is kinda the "look" Ima goin' for

But, for starters, the seat back, base boards were a bit longer (taller) than the upholstery

So, I made some adjustments (just a little off the top)

Trimmed the foam to match the base
...& (if/when possible) I left extra material for the "wrap around"
...or add some (if needed)

* It should look like a bowl when done

Rounded the top corners a bit

So, they would look about like this, when done

(1) down & (1) to go

 

[Functional Artist]

Hey, what is that spot?

IDK
It's not really a spot of "something"

It's more like a discoloration

Maybe something was sitting there (shading the "spot")
...& the sun faded the rest of the area

So, maybe the color is just a bit darker there

 

[Bansil]

What machine are you using? Those look good, I redid wife's seats in her old race truck, pulled off stock cover ,unstitched the middle part and replaced the pink/black heart and crossbones

 

[G.W]

You know, the rear seat in a jeep is a bench seat.

But if you want to do it that way I won't judge.

 

[Functional Artist]

What machine are you using? Those look good, I redid wife's seats in her old race truck, pulled off stock cover ,unstitched the middle part and replaced the pink/black heart and crossbones

Hey Bansil,
I had to hand stitch these seats because the foam is glued to the fabric
...& the foam gets in the way (keeps catching & causing interruptions in the stitching)

I re-did the seats in one of my trucks, with the upholstery out of a Pontiac Vibe, a couple of years ago
...& used a Brothers sewing machine (Wal-Mart special)

Before

After

 

[Functional Artist]

You know, the rear seat in a jeep is a bench seat.

But if you want to do it that way I won't judge.

Howdy G.W.
My mini-Jeep won't have a back seat
...just a mini-cargo area

 

[Functional Artist]

Hand sewing wasa killin' my hands
...so, I took a break
...& got (1) of the CAD fenders out & worked on double checkin' the dimensions

Looks pretty close (I must say)

Then, took 'er back to my workbench ta make some adjustments
...but, Ducky said "I'm already sittin' here"

I used the CAD fender (with adjustment notes) to make another (V2)

With Duckys help (of course)

She says "You got a problem with that? ...Denny"

 

[Functional Artist]

I made V2 ~1" wider (to come out over the tires a bit more)
...plus, I added a ~1" extra (ta bend down & form a rounded edge)
...& made some more "notes" (like how far to extend the bolting flanges)

After a bit of "trimmin'" Ducky says "I think were ready to transfer this to steel"

We have a 13" x 72" piece left (the spare body side panel, I saved in case I messed one of the original ones up)
...but, getting both fenders out of it wasn't going ta work

Re-calculating...re-calculating

If I shorten the "fancy front bend" up a bit, I could probably get both fenders out of that piece
...sometimes, with a few adjustments, you can make, what ya got ta work with...work

More "fine tuning" adjustments

* Using a "straight edge" as a guide

...helps ta make "straighter" cuts

I think got my "moneys worth" outta that cut-off wheel

 

[Functional Artist]

After cuttin', I "doubled up" them fender blanks
...& bolted 'em together, using the bolting flanges

Rough cut

The advantage of this concept is
...if all goes well ya get (2) identical pieces
...but, the (possible) dis-advantage is
...if ya mess up, they still match

Fine(er) cut

Take 'em apart
...& flip (1) over
...& now there are (2)

These are the only scraps, that we have left out of that whole 13" x 72" piece

 

[Functional Artist]

More measurin' & markin' (where ta put the bends)
...& markin' the bend orientation (upwards or downwards)

Bolted the bender to the workbench
...& started a bendin'

I installed the "outer" side bends first

Because of the awkward size & shape, I couldn't do much more in/with the bender
...so, I had ta get a bit more creative

Had ta form this bend (for the bolting flanges) using hand tools

A rubber Mallet for shapin' & bendin'
...a steel hammer for "crisping up the bends"
...& a pair of sheet metal shaping plyers
More creative clampin'
...& some hand bendin'

Flipped 'er over
...& then, bent 'er again

 

[Functional Artist]

I dry fit, the freshly formed & roughly bent, left front fender
* Yup, that's a grease gun under the mini-Jeep I gotsta grease my truck, some-a-time, today

Floorboard to body junction (He...he...I see you down there Ducky)

Fender to body junction (I'd say that's a pretty tight fit)

 

[Functional Artist]

I got an E-mail over the weekend about the Jeep Fest

Wholy Crap! we'sa runnin' outta time

We gotsta be there, ta get our spot in the parade, Sat morning Aug. 5, 2023 by 9:30am
Ducky says "we got this"?

 

[Functional Artist]

Back to the seat backs

I got the hand sewing done, on the seat backs
...but, I didn't like how the back side looked
...& they would be quite exposed

So, I added some of the cargo area floor mat material (outta the Caravan that I got the upholstery from)

Left one is just wrapped & stapled
...& the one on the right has the mat, on it, for a "cleaner look"

Close up view