Build a cheap seat - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 14 Old 01-26-2010, 12:05 AM Thread Starter
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Build a cheap seat

I tried to live with the stock seat. It's killer, no news there.

The Kawasaki gel seat was a bit better, but it was still a killer.

Hadda do sumpthin', and this is by no means original. Yeah, it's a rip-off, but, hey, I did it in an afternoon and for about $45.

The foam I used is called "rebond" in 1" thickness, and it is a good stiff foam. It is stiffer than the stock foam.

The only special equipment is an electric carving knife, a disc sander with really coarse grit paper, and 3M #77 adhesive. Oh, and the mighty PFAFF for sewing a cover...

An inch needs to come off the top...


And some from the nose area...


Then the sides start to go on...


The sides will get carved away so that there is no taper and the seat is as wide as the pan...


Then the top gets glued in place...


And it looks like this...


Now it gets carved and sanded into shape, just keep at it until it's right...


Then cover with 1/4" foam...


Sew a cover and install...


It's not perfect, but it is comfortable.

Tom

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 01-26-2010 at 12:14 AM.
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post #2 of 14 Old 01-26-2010, 12:15 AM
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NICE Tom!




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #3 of 14 Old 01-26-2010, 12:19 AM Thread Starter
Pretty in Pink, dunno why
 
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Thanks, Dan.

Tom

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #4 of 14 Old 01-26-2010, 12:21 AM
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Have you butt tested it on any long rides yet?




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.

Last edited by Lockjaw; 01-26-2010 at 12:24 AM. Reason: gremlins in my keyboard
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post #5 of 14 Old 01-26-2010, 12:41 AM Thread Starter
Pretty in Pink, dunno why
 
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Nope, only past the one hour mark. I usually start to get a butt-ache after about 45 minutes, but it was feeling real good at an hour. My butt is an ax handle and a plug of tobacco wide, though. YMMV.

I have a two-day coming up that will be the true test. If that's good, then the 9-day Tour de Dos Pendejos up through Shasta will be next.


Tom

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 01-26-2010 at 12:59 AM. Reason: replace three letter word for hindquarters with four letter word
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post #6 of 14 Old 01-26-2010, 12:48 AM
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Cool, keep me posted.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
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post #7 of 14 Old 01-26-2010, 06:51 PM
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Great looking seat. I'm pretty much copying it if I can't get my bro in law to trade. He has an '07 that I just love!
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post #8 of 14 Old 01-27-2010, 05:59 PM
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Tom you may get more work than you can handle if the word gets out. It really looks nice. Great idea! The price is right.

09 KLR 650
05 Sportsman 700
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post #9 of 14 Old 03-22-2018, 01:33 PM Thread Starter
Pretty in Pink, dunno why
 
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I've lived with that seat for seven years now. It was pretty good, but I've decided it is too soft, too flat, and too narrow. Or, perhaps, I've gotten too soft, too fat, and too wide.

The foam was cut down to the pan, save for enough to create a bit of a butt-shaped dish. 2" of stiff foam from garden kneeling pads was installed with some wings.



A cover has been made but is waiting for some 1/4" foam to overlay on the main foam and fill out the cover.


Damn, I hope this works. I've done, painfully, a few 300 miles stretches by myself in the past few weeks and, if it weren't for the fact that my buddy's Guzzi won't pass a gas station after 150 miles, last week's trip would have butt-crippled me.

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 03-22-2018 at 01:36 PM.
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post #10 of 14 Old 03-22-2018, 03:32 PM
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Looks like your cheeks will be cradled by the hands of an angel.......LOL

That appears to be more of a touring seat now rather than a dual purpose. Did you consider some of the kits such as Seat Concepts?

A wish is a desire without an attempt
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