Topic: LOWERING STAND-OVER HEIGHT on my "new" 1979 CB650 Christmas present to myself

[EZduzit]

Got back to my seat pan project today. First I tuned up the shape and added a couple wood blocks in the areas of proposed hinge and latch points. Then double-stick taped some 1/4" foam packing material to create sufficient space so the pan would not come into contact with any hard bits to transfer vibration. This foam (I had on hand) has a bit of waviness to it, so does not lay perfectly flat, but I figured this will contribute some additional stiffness to the pan. Next I completed the rough form using packing tape as a mold release. Lastly I masked the bike with poly film to protect the finish.

With the prep out of the way I roughed to size, and saturated with epoxy resin, 2 layers of biaxial cloth with matte, and applied both consecutively, without waiting for the first to cure.

[grcamna2]

You form that fiberglass into shape ?

[EZduzit]

You form that fiberglass into shape ?

I used the taped-over form (previous photo) and laid up the glass directly onto it. So I know it will fit.

Before I remove it from the bike I will mark the cut line.

[EZduzit]

Pulled it off the form and roughed out the shape. Pretty satisfied that's as low as I can make the pan without resorting to cutting bits off the bike's frame, which I had early on decided not to do.

[BenelliSEI]

That is looking very clever. Will you use an original repro cover and just pull it down and trim to suit?

[MauiK3]

Very ambitions!

[EZduzit]

Thanks fellas. Been busy with work (photo shows the milling machine mess I just walked away from today when I simply had no energy remaining ), but picked up both high and medium density closed cell foam for the new cushion. And the gel pad I ordered came in today. Also made some slight adjustments to the fiberglass to fine tune the shape of the pan.

I plan on having a local professional auto upholsterer do the cover. He did a fine job on leather seats for my Tundra, and was a good guy to work with. Did what I expected of him and was a man of his word. He has agreed to do the job once I complete the foam work.

[EZduzit]

Been so busy with physically exhausting work I've only just today made some progress on the seat.

Got most of the high density foam underlayment glued on. Built up the back sufficiently to envelop the rear fender bulge, and got 2 layers on the bottom, including an insert of medium density foam in the second layer, at the front of the seat, just under my package, to help with stand-over height (you can see the color transition in the foam, from high density to low density, just behind the tank). This was fairly tedious work, complicated by the lumps and bumps necessitated in the pan to avoid striking welded-on seat hinge supports. Following that I did a bit of rough shaping, using the electric knife, so I could test fit it on the bike to make sure I was on the right track. Felt like we're moving in the right direction. Also pretty pleased with the overall appearance.

Checking it against the original profile template, there's still plenty of room for additional padding, one of which will be the new gel pad.

[grcamna2]

Just for yourself and no passenger ?