"DIY" Seat Modification
 

I was thinking about buying an aftermarket seat after trying my friend's Sargent, but the cost was slowing me down. :eek: Lane, my friend, suggested that I take his OEM seat and see what I could do to modify it - worse case I could always buy an aftermarket seat if I mucked the project up too badly. At first I didn't think I wanted to try this but after reading Modify Seat I got enthused about giving it a try.

Before:

Attachment 8908

After:

Attachment 8909

The process: i bought $5 worth of scrap packaging foam that felt like it had the same resistance as the foam in the stock seat.

Attachment 8910

It is an inch thick and I was pretty sure I needed more thickness so using 3M' Fast Foam 74, I laminated two pieces together.

Attachment 8911

Had to do this for both sides and then glue the laminated pieces to the sides of the seat.

Attachment 8912

Next I used an electric kitchen knife, Black & Decker, about $10, got the plane of the laminated pieces to the same height as the OEM seat. Used a hunk of 22 gauge c.r.s so I wouldn't hack into the OEM seat surface.

Attachment 8913

Then I traced the outline of template made from Lane's Sargent to define the contour of the seat.

Attachment 8914

Spent some time smoothing rough edges as best I could with the electric knife.

Attachment 8915

Then it was off to a local upholstery shop to put the original cover back on (I like the non-skid feature) and add bolsters to the sides so that it could be stapled back on. I rationalized the $45 cost because I wouldn't have to buy a power stapler. I had tried my hand powered stapler and it wouldn't penetrate the seat pan to the degree I liked.

Attachment 8916

We'll see how it holds up and how much of an improvement it is. It will be pretty easy to remove the foam I added and try another type of foam sometime in the future. My cutting technique will be better the next time I do it. :D

Atta boy Rich.

I may look into that foam when I do the seat as a step up. I want to flatten the rider area on both my 650 and as needed on the 250 - no sliding into the tank - and put a slight step up on the back.

http://www.ktm-parts.com/mm5/graphic...8007240100.jpg

Ricky Carmichael's Hondas had that style seat, but his was to keep him in place under acceleration... I don't see that as an issue on the 250...:D

For those of you with the older 06/07 models, keep in mind you can buy a cheap KLX300 seat off eBay for your seat DIY projects, so you have your good OEM one untouched :)

Seatpan is exactly identical. Has same groove to fit on top of tank (even though KLX300 used a screw rather than the protrusion our tanks use).

I believe something with the seat is different in 09+ models, correct me if I'm wrong.

Nice work, oldgypsy!

I'm doing something similar to a KLR seat, but I'm using closed cell foam:

http://i1355.photobucket.com/albums/...psuvol7gph.jpg


Ron

You guys realize making those wide seats will cause trapped farts!

Besides control, there is a purpose for standing up, you know. :D

Lol, my gortex gear does that, takes about 5 mins to reach me. OMG WTF!!!

Give an update on how well its holding together please.

So far, so good.

Just after completion:

Attachment 8411

And now:

Attachment 8412

It's possible the foam that was added has compressed maybe an 1/8". I'm 79 years old, and I tend to sit vs stand more than the average rider. Unfortunately, I haven't been able to do a back to back compare with the Sargent seat, but I can still say that I've been quite pleased with the extra comfort and it seems to be holding up real well. :D

Sir, you are my Hero and an Inspiration! Thanks for posting and keep riding. I can only hope & pray I will still be riding when I reach your age (Big If). Respect! And I love the seat Mod, tried to mod mine but gave up and bought the Seat Concepts with I'm sure similar results :D