BENCH SEAT (4 OF 8)
When the new foam blocks arrived I went to work on the back. I first removed the large damaged area at the driver side with the saw and the electric knife. Then I glued in the new 24 x 24 x 3 foam block. I took the electric knife to rough out the shape, and worked it to final contour with the grinder. After I got it to shape, I installed the back cover.
Adhesive that I used - - - - - >
http://solutions.3m.com/wps/portal/3...er-77/Super77/
Then I did the same for the bottom. However, I ran into a few problems here.
1. My arrangement of new blocks that I glued in wasn’t good. It was hard to glue up and left gaps.
2. I didn’t cut deeply enough into the damaged area on the surface.
3. I didn’t have decent templates to follow for shaping. I mickeymoused one out of cardboard but it was too crude.
4. The firmness of the new foam felt softer than the original. I set the new cover over the foam and sat on it and I could feel the difference in firmness (but, the back felt OK so I left it alone).
I decided to order foam at the next highest firmness level (F=40) and redo the bottom. The first foam piece that I got from the local supplier looked to be the right choice now, so I decided to use it. I ordered one new piece of foam
17 x 12 x 6, D=2.4, F=40