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.
