Re-covering KZ400 seat

Re-covering KZ400 seat

02 Jun 2007 12:58

#145704

The pan was rusted out along 2/3 of the lip so the metal had to be replaced. This photo shows about half of the metal replaced already, and painted black, but there is a new piece going in.

Using some sheet metal from an old refrigerator.

This is just a low-budget project-bike so costs have to be minimized.

Post edited by: loudhvx, at: 2007/06/02 16:25

1981 KZ550 D1 gpz.
Kz550 valve train warning.
Other links.

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Re: Re-covering KZ400 seat

02 Jun 2007 12:59

#145705

Here's a closeup on the left front corner being done.

1981 KZ550 D1 gpz.
Kz550 valve train warning.
Other links.

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Re: Re-covering KZ400 seat

02 Jun 2007 13:00

#145706

This shows how far gone it was.

This is the worst spot. The rest is not so bad. The metal just inside of the lip is pretty good. Looks like water collected at the front left corner, since the bike leans that way.

Post edited by: loudhvx, at: 2007/06/02 16:02

1981 KZ550 D1 gpz.
Kz550 valve train warning.
Other links.

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Re: Re-covering KZ400 seat

02 Jun 2007 13:04

#145707

After the lip was replaced it gets some cheap black paint.

1981 KZ550 D1 gpz.
Kz550 valve train warning.
Other links.

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Re: Re-covering KZ400 seat

02 Jun 2007 13:07

#145709

The seat is to be shaped differently, but it comes out so rough when it is cut with a knife.

1981 KZ550 D1 gpz.
Kz550 valve train warning.
Other links.

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Re: Re-covering KZ400 seat

02 Jun 2007 13:10

#145712

Someone on KZrider (I'm really sorry I can't remember who) had the great idea of using an angle grinder/sander. Man it works way better than I would have expected!

I smoothed this in just a couple minutes. (Be warned, do it outside, foam goes everywhere!)

From experience, I know it doesn't have to be very smooth. The vinyl hides the roughness of the foam, so I didn't spend much time on smoothing.

1981 KZ550 D1 gpz.
Kz550 valve train warning.
Other links.

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Re: Re-covering KZ400 seat

02 Jun 2007 13:12

#145713

The pan has a bunch of dimples and uneven spots. The plan is to have minimum seat height, so to fill in the dimples I just siliconed in some foam chunks.

I forgot to phot it, but those big pink pads in the background are carved out on the bottom to accept some of the bulges in the pan.

Post edited by: loudhvx, at: 2007/06/02 16:14

1981 KZ550 D1 gpz.
Kz550 valve train warning.
Other links.

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Re: Re-covering KZ400 seat

02 Jun 2007 13:16

#145714

Here's what we are shooting for. The seat is going to an upholstery shop for a new cover. I will put up a photo when it's done.

I'm not sure we can get the seat as low as this photoshop version.

1981 KZ550 D1 gpz.
Kz550 valve train warning.
Other links.

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Re: Re-covering KZ400 seat

02 Jun 2007 16:17

#145746

loudhvx wrote:

The seat is to be shaped differently, but it comes out so rough when it is cut with a knife....

Never tried a sander, but a hacksaw blade or an old fashioned "bread knife" cuts through foam easily and cleanly with no chunking.

1973 Z1
KZ900 LTD

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