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Post Info TOPIC: T-Bucket upholstery - bench seat build and door panels


OSHAWA, ONT

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T-Bucket upholstery - bench seat build and door panels
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After reading/posting in another post, I remembered I had this posted at the HAMB and thought I would share the info over this way.

 

Okay, I know it's a t-bucket and the build is OT, but I figured I would share my first attempt at some seats.

A couple months ago I had determined my seat rake and height using a stash of 2x4's, 2x6's, plywood and foam. Now all I had to do was make it all work:

First up lower seat supports:


Then came the base: Lots of tweaks, sanding, more tweaks. Then I finally realized that they do have to be so exact as vinyl, foam and side panels will all take up space, once I figured that out things when a little faster.



Since I have no padding on my ass I wanted a soft seat, so I decided I was going to use webbing to make things more comfy, the original cutout for the webbing:


After showing this on another site, it was pointed out that the opening for the webbing was to small as I would be sitting on the plywood and the webbing would not be doing anything, so I adjusted the width and made the openings bigger:


I then attached the supports to the base:


Once the base was built I started on the back. The first "design" did not work out as planned, so instead of wasting a good hunk of plywood, I used it to make a template:


I then transferred to another piece and cut out the back:


Once the back was in, I started looking a little closer and realized there was a couple inches of wasted space in this design:



So I took a little from some chair building and decided to make a sculpted back (think muskoka chair), I mean what the hell, if you are going to do it, might as well make it complicated!!

Here is the back with the webbing area cut out, the strip in top is the template for the wood needed for the sculpted area:


Transferred to some more plywood cut out and glued up. Then came the fun of making it fit as I wanted, which included sanding, sanding, some more sanding, shredding the last belt I had before finishing, and you guessed it more sanding. Here is the result:


The shape of the cutout mirrors the contours of the body:


Then came the webbing, I have been told, and I am sure I will here again that I used to much webbing, but webbing is cheap and its easier to remove a belt at a later date:

I had to go out looking for "seat" webbing instead of "back" webbing yesterday, luckily I found some, it has less stretch then the back stuff, anyway, here is the start of the bottom:


I have a new appreciation for those that do this work a lot, after doing the bottom and back my hands HURT from stretching the webbing out!

Bottom finished up:




Then I did the back, this was a little different due to the curves, but the same result:




Here they are installed:





Even with out any foam, they are pretty comfy. I was told the best way to test them out is to just sit in them for a couple hours, I think I will do that while watching the hawks tonight, should be a good test.

Now that these are finished I can finish clean up the wood in the cab and take it back outside for some glass work.

Once I got the webbing sorted out I started on the foam. I was planning on using 2 inches of C45 foam with 1 inch C45 for the bolsters. I was told I would need at least 3 inches of C45, so thats what I went with. Of course When I originally set up the seats and body wood, I was planning on 2 inches of foam, needless to say I had to do some trimming.

Here is the base foam glued up, I missed a step or two here, sorry.


Then I marked out and trimmed some contours into the foam, I started using a flapper disc on a grinder, and it was way to awkward as evidenced by the slip there on the left. I finished up just using the electric knife, turned out to be much easier to control.




Once I had that sorted out I went a head and tested the fit in the car, this is where I noticed the extra inch....it totally threw off the feel of the seat.



So I marked out an inch and proceeded to cut, chisel, swear a bit, and chisel some more to get that wood out.



Now the seat back was back in its proper place:



Next up was the back, for this I used 1 inch of c35 for the base, and another inch of c35 for the bolsters, this shows the contour of the seat itself:



Next up was to add the bolsters:




I then trimmed the contours and tested the fit:




Everything looked good, and more importantly felt good, even the wife approved when I drug her out to the garage for a test sitting.

 



-- Edited by Keeper on Saturday 3rd of May 2014 08:34:00 PM

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OSHAWA, ONT

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I got some patterns done tonight, but these will be the base for the covers. I expect I will make these covers at least twice so I went ahead and made a full set of patterns. Here is how I did it.

Supplies: (Well what I used anyway)

Carpenter square.
Long straight edge.
Poster board.
pencil, marker
razor
scissors
acetate (clear vinyl for patterns)
And of course the seat.



I started with the poster board, I made a few mistakes then realized, I only had to make one side, then copy it for the other....



Complete set:


I then transferred the patterns to the clear vinyl adding the 1/2 seam allowance.



You cannot really see them in the pic...now I can move on to the vinyl.

OKay so I took a stab at making the cover bench cover. This is my first attempt of doing anything like this so it took most of the day to do the bottom. Hopefully the top will go a little quicker. Not that it matters much!

So here we go:

Transferred the patterns to vinyl:


Cut it all out and transferred the reference marks.


Glued it to foam and cut it out, marked out the pattern and sewed them up (forgot to take a pic) I went with 1 1/8 between pleats.


Then I jumped in and started sewing. This was the easy part. I did not go with any decorative seams as I am not confident enough in my skills to do so. Maybe on the next set.


Next the centers: Starting to look like something now.


Then came the skirt. Next time around I won't center the seam!




SO CLOSE!!! Even with all the reference marks, I some how missed the point......It did not really show up until i started stretching and stapling.


Lots of stapling:


And the finished seat bottom:



All in all I am happy with it. I will do a couple things differently on the next version.

Those that are wondering, the final version of this seat/interior will be a much lighter grey.

Now I just need to do the back.



-- Edited by Keeper on Saturday 3rd of May 2014 08:28:54 PM



-- Edited by Keeper on Sunday 4th of May 2014 07:42:22 PM

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OSHAWA, ONT

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T-Bucket bench seat build, with upholstery
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I continued on with the interior tonight. Screwed it up once, got lucky and repaired it without it showing up in the final product. Here we go:

Laid out the pleats:


Skipped a couple photos!! Here is the main panels sewn together:



After I had these sewn together I put it up next to the base and stared at my mistake, somehow I added the seam allowance in the middle panel twice, so it was an inch to wide, resulting in none of the panels/pleats matching up. I am still scratching my head trying to figure out how I screwed that up!

So I ripped it apart and hoped for the best:


Trimmed the extra off (then went and fixed my template!!):


Then sewed it back up, I moved the pleated panel in 1/8 an inch to cover up the holes from my mistake, I got real lucky this time, all part of the learning curve I guess.

Here is the cover loose over the seat, I need to pick up some listing wire before I can do the final install.



Once I tighten up the cover, the pleats will match right up:


I still need to add the listing wires and staple it to the seat back, I will post up some final pics later tonight.

 

And finishing the seat:

Added the listing:


Tada:


The back: just bacause


And installed:



-- Edited by Keeper on Saturday 3rd of May 2014 08:29:37 PM

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OSHAWA, ONT

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That was my first attempt. I had some issues to fix, so after a year in the car I yanked it all out and did it once again. This time I used some better material and changed the colors up a bit. Of course I did not take any pictures during that build, but here is the finished product:

 

2%20Jun%202013%20017.JPG_595.jpg



-- Edited by Keeper on Saturday 3rd of May 2014 08:32:30 PM

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OSHAWA, ONT

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RE: T-Bucket upholstery - bench seat build and door panels
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To continue here is the first set of door panels I did for the bucket again these were redone last year.  (See above pic)

This is a continuation from my bench seat build.

Here is how I went about creating my door panels, the plan was to match the seats, and to run a 5 inch border around the bucket, this measurement came from the distance between the top of the seat back and the top of the body.

Here goes:

First step template, both sides matched so it made things easier:


Transferred to 1/8 baltic birch plywood:


Copied for the other side:


For the door panels I plan on a 5 inch dark grey top that follows the contour of the body, with the bottom being black pleated vinyl. Here are the steps of me making the pleats....all 47 of them:

Laying out the lines: (They are 1 1/8 apart)


Weapon of choice for this task:


Almost half way through, the toughest part was fighting the awkward roll:


All the pleats done, I found it easier to sew all the pleats at once, from this I will cut out the two panels:


Not the best of pics:


Traced out the templates:





Cut out the little piece first, I was scared to cut the pleat panel...lol Give you an idea of the look



Then I just jumped in and cut and sewed them up:



Here is a small preview of what it will look like when done:



I finished up the passenger side panel:



Here is how I attached it to the plywood, helps having a beast as a machine Though next set will be on PVC.



Then I just had to repeat for the other side and hope it all matched:



Once the panels were done I started looking at the firewall and realized I might have enough pleated stuff left over to make a cover and I lucked out!

So here is the completed interior, well minus carpet.










Couple things I noticed:

Since I made the pleats parallel to the floor, they look like they are leaning forward, not a big issue but it is something I will correct in the next edition.

 



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OSHAWA, ONT

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So there you have it.

This all came about with me shopping around for upholstery. I was quoted around $3000 from some local shops and thought that it was insane for such a small car. Well after all that I can completely understand the pricing.

Anyway.

I have $650 in the machine. That gave me $2350 worth of materials to screw up before I lost money.

I bought a couple upholstery books and learned to sew, I made seat cushions, recovered some bar stools, all to get a feel for the machine and mostly the process.

I used mostly the offcuts or the bargain vinyl at your local fabricland.

I made a ton of mistakes along the way (as you can see in the following pic)  I also learned that working with fabric is much more forgiving then vinyl.  Fabric if you screw up a line, you stop pull the thread and resew it, vinyl you cannot do that as you now have a run of holes where you screwed up, the only way to fix it is to shorten the seam and hide the holes, which leads to all sorts of other problems, like mismatched seams.  See the outer edges in the following pic.  I screwed up one side, so I had to go back and make the other the same, and it made them smaller then the rest, and looked like crap.  Luckily this was a garage seat so it did not matter.

15%20apr%202011%20004.JPG_595.jpg

I found the upholstery group on the HAMB to be a huge help as there are some great how-to's on there.

Once I got a bit more comfortable with the machine, I grabbed and old computer chair and striped it down and recovered it. This helped with templates and working with bigger, bulkier pieces.

5%20mar%202013%20003.JPG_595.jpg

Thanks for looking!

 

(That chair is forsale BTW...lol)

 

 



-- Edited by Keeper on Saturday 3rd of May 2014 08:50:55 PM

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CAMBOURNE, ONT

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Awesome job! Looks better in person.

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WATERDOWN, ONT

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Great threat Brian,I have been thinking along the same line,,I have a raty interior in my coupe it is comfy,but not pretty and I'm thinking maybe I should invest in a sewing machine

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NORTH BAY, ONT

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Thanks for the great post and pics, real neat!!

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OAKVILLE, ONT

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about 40 years ago I upholstered my old lazy boy button tufted.I thought that was a hard job seeing your work I look back and realize it was like putting on a glove.needless to say you are doing very good I like also that you persist in improving.Barry

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ST MARYS, ONTARIO

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Awsume post..Thanks..



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PORTLAND, ONT

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HI KEEPER : What a great " thread " -- A fabulous piece of workmanship . You say you are an amateur -- Well , it sure is an inspiration to those of us that are still wanna-be's -- Great work and THANK YOU for sharing --- DON / fleet 51

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OSHAWA, ONT

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Thanks.

That's what its all about, jumping in with both feet, learning something and passing it along.



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OSHAWA, ONT

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Great work Brian, wanna make up a roll of pleats and sell it to me? Lol (I'm serious)

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CAMPBELLFORD, ONT

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Excellent post, some guys just have what it takes to do the task, I am amazed daily with this little group and the skill set..
I still say we need to take over a small community in my neck of the woods and build a hot rod village for the benefit and exchange
of skills amongst our own community...

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NIAGARA FALLS, ONT

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Thanks for posting your project. Excellent job on your interior. I,ve been putting mine off because of the cost to ship it out but you give me inspiration to try. Thanks again.

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OSHAWA, ONT

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Forgot the carpet!

Next up was the biggest task, carpet.  This is another first for me so it took a couple days to get it finished,  but turned out great:

As with anything I have done with this I started with some templates:



Then I practiced a bit on some scrap and figured I would tackle the mat for the bed first for some practice.  I had found a "How to" on the HAMB for making floor mats and followed his instructions on making mine:

Cut to fit:


Then the edging:


Detail of the edging, this was done in two steps, first step was to sew it to the top, then the second step was folding it over and under and sewing the top stitch, pain in the ass but worth it.



Once I was satisfied that I would not hose it up to bad, I started on the inside:

Cutting and fitting:



Then the edge work:



Of course there was not a straight edge on it just to make things easy.....

Once that was done I had a couple small things to tackle:

I was not at all impressed with the look of the shifter console, the black plastic just looked cheap, so I made a cover to match the rest of my interior:

Before:


cont...

 

After:



Then the e-brake needed a cover:


Then came the fun part of installing it all, over all I am extremely happy with how it all turned out, I also now understand why they charge so much to do a full interior.



Some details of the details:  I did not like the way the carpet frayed around the brake pedal, so I did the edging on that opening as well:


Completed interior:



Next up, the dash.  That and I still need to make a gas pedal, which I have purposely held to the last... :)



-- Edited by Keeper on Tuesday 6th of May 2014 12:42:52 PM

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THORNHILL, ONT

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Just found this thread. Great job for an "amateur". I'm inspired yet again!

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CLINTON, ONT

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Awesome  biggrin    actually very professional    and the photos  smile  excellent !!

 

He says   "Hey Dear"   I'm going to the garage, to make a "complete interior" for the Hot Rod....      

 

I have trouble matching up socks    

 

So many guys here   with so much talent.......



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NORWOOD, ONT

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Very Good Thread thanks for sharing..

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CAMBRIDGE, ONT

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Wow well done looks great

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BUCKHORN, ONT

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Great Job saves a lot of money doing your own stuff  it takes a lot of thinking to make it look that good and  nice stitching  thanks for sharing . I just sunk the floor on my T it was to windy  up there and the bugs hurt . Cheers Dana



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BRADFORD, ONT

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Nice job. Excellent post.

the Kid

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MISSISSAUGA, ONT

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Great thread, thanks for sharing with such details! Looks good in the car!

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