Epic 68 Polara bench seat rebuild for originality

[HWYCRZR]

Those with experience could probably do it in half the time as they know the short cuts and how the final product lays on the seat frame contours.
I am new and second guessing my measurements. This takes some time.

 

[Polara_500]

Well, once you get it get it figured out I'll bring my Polara seats down...............

 

[HWYCRZR]

Now I am looking for advice on inner materials.
I will also have to go visit my friends at MAC’s Hardware, they have a decent supply of upholstery materials and a couple of ladies that have been there for years, to see what they come up with.

First, the wire stays going through the burlap (first layer). It is like spring wire, thin but wanting to retain its shape. I did some internet searches, but not sure how to narrow it down to find some. I don’t really know what to call it.
Any ideas?

 

[MYSINBIN]

Now I am looking for advice on inner materials.
I will also have to go visit my friends at MAC’s Hardware, they have a decent supply of upholstery materials and a couple of ladies that have been there for years, to see what they come up with.

First, the wire stays going through the burlap (first layer). It is like spring wire, thin but wanting to retain its shape. I did some internet searches, but not sure how to narrow it down to find some. I don’t really know what to call it.
Any ideas?
View attachment 176207

I'm guessing here, but try searching for: listing wire

The bows in a headliner are called that as well.

Hope the input helps.

John

 

[HWYCRZR]

Second layer.
2”Cotton batting.
Should I stick with it or do I use a layer or two of automotive carpet underlayment? And thicker foam? I am afraid of making it too soft, but I also hate seats that feel like sitting on a brick.
I need a total of about 3” inches thickness.
I am thinking I could do a layer of the underlayment (1/4”) a layer of 1” high density foam, and finish it off with 2” medium density foam?

 

[Big_John]

Try this place. Upholstery Supplies, Upholstery Fabrics, Upholstery Foam For Furniture, Auto, Boats, Commercial

They also have different density foams. Upholstery Foam Padding & Batting, Upholstery Padding Sheets & Cut Foam

I used a "medium firm" for the seats in the 53 Windsor and a lighter generic foam for the seat back.

 

[Big_John]

This is what I did.. Starting at post #38

1953 Windsor

 

[HWYCRZR]

Well, once you get it get it figured out I'll bring my Polara seats down...............

It might be like shingling a roof.
I did it once on an addition and said no more. I did it again on my house after a hailstorm and said no more. I did it again on my garage, I mean it this time, no more.
What I am saying is there may be a chance.

 

[HWYCRZR]

I went to the local MACS Hardware, which has about 100 years of upholstery experience if you go the right day. I took in my spring wire burlap

To find out where I could find the spring wire. She had no idea, but they used to sell the burlap pre- made with the spring wire. But when they remodeled about 10 years ago they quit carrying it. She then called an upholstery guy who actually took the last ones she had to see if he had another source or a source for the wire. Nothing. The best part is nobody knows what this damn thing is called. The closest I got was burlap seat cover with spring wire. The measurement of the wire is .047 which is about 18 gauge. I googled 18 gauge spring wire on amazon popped up with high temper spring wire. I believe it is used for jewelry. I ordered 2- 46’ rolls for $11 each. I will see what I get.

Right after I ordered it I googled burlap seat covers with spring wire, and did find some burlap with inserted wire, but for a corvette bucket seat (too small).
Hopefully the wire I ordered will do the trick.

 

[HWYCRZR]

Cut out burlap for the wires. There are a lot of wires. 273’ of wire

I pleated and marked the burlap. I should be able to cut the wires to length and thread them through to get an even pattern.

41 hours into it not counting trips to the upholstery store and research.

 

[HWYCRZR]

Seat Frames ready for blasting.

I need to dig my green house frame out of the trees and set it up. This is going to be my blasting tent outside the garage. It should help keep some of the shrapnel contained and make it easier to clean up. And provide a little protection from the elements.
I tried to dig it out of the snow bank the other day but was frozen in. Then we got another 4” last night and supposed to get around 8” tonight. May have to wait a few days.

 

[HWYCRZR]

Finished one front seat back cushion.
47 hours in.

Front seat back cushion made up with burlap stitched to a couple of layers of cotton batting with another two layers covered in cheese cloth. I have a little more stitching left around the edges, but seems to be coming along. I would rather have used my sewing machine, but 2” thick is a little much. The tension would have been too tight and too small of stiches. I had to invest in a sewing awl and learn how to use it. $7 Harbor Freight.

Tearing old apart for patterns

Using a sewing awl to loosely stitch the burlap to the lower layer of batting to keep the batting from migrating and getting lumpy. Used #77 spray adhesive to attach the batting first. The sewing awl is an art, but now am pretty quick with it. Although I need a spool winder to reload the thread. It takes for ever to reload by hand.

I found the perfect tool for cutting out the batting. This rotary cutter is perfect. Kind of spendy for the cutter and pad, but Joanne’s Fabric had them for 40% off. They also usually have a 50% off coupon as well.

New and old. The topside is covered in cheese cloth to help slide the covers over the cotton batting.
A little more stitching around the edges and then in to the second front seat back.

 

[HWYCRZR]

Other front seat back complete. I wanted to start the front bench, but ran out of cotton batting. Had to order more.
When stitching with the awl I found that it was much quicker just to run the thread from the big spool through the awl. It took too long to hand wind the small spool that goes into the handle.
Getting better with the awl and is going faster.

Finished both front seat back cushions. Second one turned out better, but both should sit fine.

 

[HWYCRZR]

Took my seat springs to MRC (same guys doing the paint) to get them blasted and epoxied. I was going to do it, but would have spent more time getting my equipment set up than it’s worth. Plus it is still too cold to paint outside. Took a couple of pictures of the car in final paint. Plan on color sanding next week.

 

[HWYCRZR]

I probably need to get back to my cushions. My seat springs are done. And I just received my vinyl from SMS.
I ordered it on March 14 and received it today, May 26th. A good two and a half months later. Not a problem as I am not quite ready for it yet.

 

[1978 NYB]

Paint looks nice!

 

[HWYCRZR]

I am now 68 hours into my upholstery.
Stitched the front bench seat pad that goes under the foam. Cheese cloth over about 2” of cotton batting with burlap wrapped around the bottom. And light stitching to stake the batting.

 

[HWYCRZR]

Also did the rear seat back of which this is the only cushion. There is no foam. Only Cotton batting with cheese cloth wrap. Original cotton batting was a little more dense than new batting. It is constructed in two layers. Bottom layer is about 2” thick with the batting stitched to compress it and stake it from moving. Top layer is also about 2” but the batting is wrapped in cheese cloth with just the edges stitched to the bottom layer and a couple of random stitches to stake the batting, but still leaving it soft.

Old and new.

 

[65sporty]

You are braver than me, looking good. Keep up the great work

 

[HWYCRZR]

You are braver than me, looking good. Keep up the great work

Thanks. The scary part is going to be when I have to start assembling my seat covers. The stuff I am working on now will be the foundation, but hidden.