New Thigh Bolster Foam(S)

[dch1950 37 1 Cars]

Hi all,

It's been a busy start to the year for me and this week I finally got my prototype thigh bolster mould made. Pattern making was not high on my list of personal skills so I had to spend sometime "teaching myself" how to approach this job. The GRP mould is undergoing final surface finishing and then goes for it's pre-production wax treatment. I am planning to do the first casts next week, and if all goes well then the first production batch will follow after that.

My steep learning curve will prove useful in producing the LHS moulds though and I should be able to get that in production within a further week or so.

My initial price estimate of £35 each has had to increase slightly due to increased estimate of raw material costs but they will come to market at £38 each + P&P.

I will produce these, initially, in batches of 25 and these will be available through my web shop or by contacting me directly. Watch this space!

best regards

Dave Hickman

PS here's a piccy of the first mould.

 

 

[madspikes 41 1 Cars]

Good luck with this, I'm sure your get some takers. These could be the next big thing, its beam refurbs at the moment maybe it will be seat bolsters this summer!

 

I had this seat bolster idea idea back in 2005 but I never really got much further than the idea! Must progress some of my other ideas!

 

Mad

Edited March 6, 2011 by madspikes

[dch1950 37 1 Cars]

Good luck with this, I'm sure your get some takers. These could be the next big thing, its beam refurbs at the moment maybe it will be seat bolsters this summer!

 

I had this seat bolster idea idea back in 2005 but I never really got much further than the idea! Must progress some of my other ideas!

 

Mad

 

Beam refurbs are so last year.

D

[Retro Pug 0 1 Cars]

Loving the work so far, I will definately be interested when the time comes.

[dch1950 37 1 Cars]

Hi everyone,

The first casts/mouldings were made yesterday. I haven't seen them yet and so am travelling into Coventry this AM full of anticipation. If the basic mould is proved OK then we just need to settle on target density. This WILL be greater than the original.

First production run will follow from this. I will be making a LHS mould as well as they both get damaged although it tends to be the front (nose) section of the passenger side that fractures along the diagonal.

It seemed to make sense to me to provide the bolsters before the new covers as there didn't seem to be any point putting new covers over old tired foam.

The insert material (red/black check - that I over ambitiously named "Quintet") is another story and has not resulted in the great success I was anticipating. Followers of my web site will now that this great looking fabric wouldn't (unfortunately) stand up to any kind of wear at all. I got really suckered by a Middle east firm that claimed to be a current Peugeot seat fabric supplier (and hence they knew all about it - WRONG). Never mind I will produce other seat variants which will look good.

So - my first product is close to launch now, and the next 2 are being planned.

Keep the faith.

regards

Dave

[cRaig 265 1 Cars]

So does that mean replica seat covers are off the cards permanently, or have you got other suppliers in mind?

 

Regards

 

Craig

[dch1950 37 1 Cars]

So does that mean replica seat covers are off the cards permanently, or have you got other suppliers in mind?

 

Regards

 

Craig

 

No it doesn't mean replica covers aren't going to be made. It does , however mean that those covers which require the "Quartet" insert can't be made just yet.

What you must understand is that this fabric can't just be ordered up ex-stock. Any potential supplier treats this a private commission from me (funded by me)

I was let down by a "clown" - but fortunately I wouldn't buy that material until I saw the test certifications.

I am looking for alternate textile manufacturers who can actually do this repro type work, but it's not easy as most of them just want to sell you what they've got rather than what I actually want. I'll get there though.

Meanwhile I will move to bolster covers (B09 needle cord) and then to the Rallye seat covers along with Alcantara and leather combinations - these I think will be a great replacement cover (of course I would say that !!). The problem I've always had with the Peugeot Quartet" fabric is that you can't really re-use it now as it's knackered and new bolster covers sewn to old inserts was never going to work.

This is where I'm at currently

Thanks for your continued interest.

regards

Dave

[cRaig 265 1 Cars]

Well, its good to hear you can kick off the business with rallye covers and new bolsters

Best of luck tracking down another supplier!

[dch1950 37 1 Cars]

Hi all,

just back from Coventry - and the first one out of the mould is looking OK. A few snots to clear up but it's basically there.

 

Drivers side thigh bolster:

 

 

[lemmingzappa 75 1 Cars]

Impressive work !

[jeremy 68]

Hi, again following another one of your very interesting seat threads. It is not my intention to tel you what to do, but seeing as this is a business, would it not be a good idea to see if there are other car seats requiring bolsters, as I would have thought that perhaps this would be easier and more cost productive than (assuming here) trying to find the seat inserts. I know this defeats the object of what you want to achieve, but may just prove a little easier and lucrative.

[dch1950 37 1 Cars]

Hi, again following another one of your very interesting seat threads. It is not my intention to tel you what to do, but seeing as this is a business, would it not be a good idea to see if there are other car seats requiring bolsters, as I would have thought that perhaps this would be easier and more cost productive than (assuming here) trying to find the seat inserts. I know this defeats the object of what you want to achieve, but may just prove a little easier and lucrative.

 

Hi Jeremy,

I'm not trying to find other marque inserts - so the question will never arise.

If you check out most of the owners clubs you nearly always find someone specialising in covers, or trim or even foam. Indeed whilst doing my research I came across quite a few. The guy I'm working with in Coventry is thinking of doing Truimph Spitfire seats (fully moulded) and it may be that a joint venture whereby I sew the covers may (and I stress - may) occur. At the moment I have enough on my plate though. RHS bolster to finalise, the LHS mould and pattern to make up etc,etc.

I haven't got to the actual covers yet - having suffered repeated knockbacks by Auto textile manufacturers who generally do not want to know about my requirements and more intent on selling me their latest range of Bus,car,SUV fabric etc,etc,etc. as a "Quartet" substitute even though it is nothing like it!

The devil is always in the detail with these things - at least it is as far as I'm concerned.

Thank you for your continued interest - and as you know by now - "keep the faith"

regards

Dave

[weejp 0]

I'm looking forward to the final results, great stuff. I will 'keep the faith'.

 

Good luck.

[dch1950 37 1 Cars]

Hi all,

I finished the RHS pattern insert yesterday and after preparing it (essentially covering it so that glass fibre doesn't melt it!) I dropped it off at the mould makers. This one should be ready for me to pick up this Friday. I then have to spend 2 or 3 days final finishing the inside faces prior to an initial product run.

The LHS insert and mould was also final finished along with a small fillet piece that needed to added, this was also dropped back to the foam moulding shop and the first actual product will be ready for me to inspect on Friday. Once I'm happy with the density RHS will then go for first full batch runs next week closely followed by the LHS bolsters (approx 3 days behind if all goes well).

regards

Dave

PS

Great stuff this Aluminium foil tape!

 

 

Edited March 16, 2011 by dch1950

[d7ve_b 44 1 Cars]

Looks good, I'd definately be interested.

[dch1950 37 1 Cars]

Hi all,

I picked up the RHS (driver) first production cast this am. I have upped the foam density by 10% over the original and it feels much better. I also added a fillet piece to create a bevel along the bottom inner edge - this will save manually trimming it. A quick comparison piccy is shown below.

I also went to the GRP moulders to pick up the LHS master mould. As I spent more time on the second mould template piece, it has paid dividends as there is less work required to smooth out any wrinkles in the resin. This means I shall be able to prepare for world dominance this weekend - after the Rugby , of course.

All is proceeding to plan, and schedule, and thus I will be coming to market (both sides) by the last week of March.

regards

Dave

 

 

[d7ve_b 44 1 Cars]

Put me down for a RHS one.

 

If you haven't already considered it, it would be good to include in the price/product a guide for replacing the bolster

[dch1950 37 1 Cars]

Put me down for a RHS one.

 

If you haven't already considered it, it would be good to include in the price/product a guide for replacing the bolster

 

Hi,

if you have followed my threads on seat covers and bolsters over the last 10 months you will know that I have already produced a general guide to bolster repair - available as a .pdf download from my web site. Because of the slightly tricky nature of replacing the foam (from the point of view of where you cut the old one out etc)I have decided to make a "youtube" video of how to do it. Watch out Spielburg, Hickers is coming.

Thanks though for thinking ahead.

regards

Dave

PS what do you think of the replacements?

[d7ve_b 44 1 Cars]

Sorry, I haven't seen the previous threads, it seems I'm well behind the times so I'll keep my big mouth shut!

 

As you've probably noticed I'm no expert on the construction of the seat foam/bolster but it looks like it's made to a high quality and will likely be a massive improvement on existing crushed bolsters.

[jackherer 543]

That looks great, there is obviously a big market for these so you should sell loads.

 

Are you planning on putting before and after pics on your website? A pic of a 205 with a typically collapsed bolster and a pic of the same car looking as good as new (or 10% better even ) would be very striking I think.

[dch1950 37 1 Cars]

That looks great, there is obviously a big market for these so you should sell loads.

 

Are you planning on putting before and after pics on your website? A pic of a 205 with a typically collapsed bolster and a pic of the same car looking as good as new (or 10% better even ) would be very striking I think.

 

Would I be so flagrant at marketing my own product - shame on you. You only have to look at the before pictures of my knackered old seats to what "before" looked like. ( Note to self -I must try harder on the seat covers though). No seriously I hope you are all getting used to my sense of humour now, but also realise that I am very thorough in my projects. The Aussie frogs guys are getting really interested as well so I think things might be starting to come together.

thanks mate.

regards

Dave

[dch1950 37 1 Cars]

Morning eveyone,

Here's a shot of the driver side replacement foam actually in situ. It fits in nicely don't you think?

 

 

It is also worth mentioning ( for those of you who are interested at least) that when I stripped my work in progress seats down last summer I actually washed the foam inserts in the washing machine (low temp wash) and let them air dry. Didn't take long and they are much better for it.

If you are just doing the one bolster then the forum instructions (by J Turnell) are more than adequate and I recommend their use.

 

My second product due shortly , is replacement cloth bolster covers and then a more extensive set of instructions will be needed relating to seat stripping and reupholstery (or maybe a youtube video clip).

 

Hope you like this stuff.

regards

Dave

[dch1950 37 1 Cars]

Hi everyone,

I have been headbanging with Peugeot UK lately and it has made me a bit irrascible. Sorry about that.

Today I'm working on the LHS GRP female mould, mainly filling and sanding to remove rough/high spots (snots). I also beefed up the insert lids as making 50 is a bit different from making one. The RHS lid just needs a clean up and a rewax and that is ready to go.

My GRP moulder really liked my use of the aluminium foil tape as a barrier to protect the actual foam - I can see he'll be using that technique soon. It also allows for fine surface detail to show through, bit of a pain as far as I was concerned as there was some gaffer tape holding the foam together (usual split in the top) and it wrinkled a bit so I have to skim and sand or else those wrinkles will be reproduced for everafter.

 

Here's a snap of the RHS female mould just for completeness along with it's insert.

 

 

 

 

 

regards

Dave

[cRaig 265 1 Cars]

Looking very smart, as usual! Bolster looks particularly good on the seat!

[dch1950 37 1 Cars]

Looking very smart, as usual! Bolster looks particularly good on the seat!

Cheers mate, also heard today (after nearly 7 weeks!) Peugeot have granted me permission to use the "Flamme" logo on my version of the "Rallye" seats.

I do like it when a plan comes together. I am going to see a an auto pattern maker tomorrow with a view to making a more durable set of pattern inserts.

Should be fun - it's years since I did any NC programming. Happy days.

regards

Dave