New Thigh Bolster Foam(S)

[dch1950 37 1 Cars]

Hi everyone,

Both the moulds and the inserts are now completed (LH & RH sides) and they go back to the moulders for the first production batch today. This will comprise of 10 LH and 25 RH bolster foams. Dependant on the shop loading these should be available for puchase from Wednesday of next week (30th March). This means I just managed to get to market before Q2. Nice one Dave! (Note to self - must do some sandbox test orders through the web shop).

All going well I am now looking to get the pattern insert parts CNC routed from a single piece of material as this will be more robust and will stand up better to the rigours of the production environment and will also enable faster reproduction of the said parts.

This should effectively finish off the pre-production phase for the bolsters and will let me concentrate on product #2 & #3. These will be replacement bolster covers (seat and squab) in cloth and then a full "Rallye" seat cover(s) with emboidered "flamme" ( and you all know the story behind that one!)

The past few days have been informative as I spent one with an old style pattern maker, and one with a CNC programmer - the same end product , but worlds apart in the route chosen to get there. Very interesting.

I know have to re-familiarise myself with CAD/CAM progs (Mastercam - specifically). I know one thing - I am getting loads of new skills doing this project and I've only just started really. Great fun.

regards

Dave H

[johnnyboy666 195 1 Cars]

Every time i read one of your threads about this project dave, I am astounded by the level of attention to detail that you put into your work! I'm curious, will there be 'kits available, e.g two bolsters and a full set of seat covers? Or perhaps just a full set of seat covers on there own and bolsters seperately as required?

I'm not sure If this is something you had thought about already, but selling these on ebay could well be very lucrative for you, as I'm sure, like a lot of people I regularly do a scan of 205 stuff on ebay to see if anything interesting is about. And this is definately interesting!

And lastly, would there be an option later along the line for people to supply you with a material for you to make custom seat covers with? (can you tell I'm thinking of some interesting possibilities!)

cheers

john

[dch1950 37 1 Cars]

Every time i read one of your threads about this project dave, I am astounded by the level of attention to detail that you put into your work! I'm curious, will there be 'kits available, e.g two bolsters and a full set of seat covers? Or perhaps just a full set of seat covers on there own and bolsters seperately as required?

I'm not sure If this is something you had thought about already, but selling these on ebay could well be very lucrative for you, as I'm sure, like a lot of people I regularly do a scan of 205 stuff on ebay to see if anything interesting is about. And this is definately interesting!

And lastly, would there be an option later along the line for people to supply you with a material for you to make custom seat covers with? (can you tell I'm thinking of some interesting possibilities!)

cheers

john

 

Hi there John,

If you check out my web site you will find a pdf download of proposed inventory and current prices. I know Fleabay is an active market place - but commission fees always keep nibbling away at my margins so an Ebay shop is not for me really. (fees for paypal, sellers fees for Ebay etc,etc) Custom covers - interesting , a variation of this was when I considered using customer Quartet inserts with my cloth bolsters - didn't like the idea of that as most red/black check seat inserts are well and truly S**T! Maybe new customer insert material for incorporation into my seats - a possibility.

I am a theoretical physicist and computer systems designer by previous life trades and I dare say just a tad "anally retentive" combined with a healthy dose of obsession. Hope that goes some way to "the DCH view on the cosmos".

I will eventually climb up the search engine rankings so you will get to me anyway via 205 covers, bolsters, foams etc,etc,

Keep the faith.

regards

Dave

PS Brian Cox is a *****CENSORED****

[johnnyboy666 195 1 Cars]

Fair enough on the ebay front, it can be expensive, but i was thinking along the lines of just listing one product, that sells well, then adding a link to your website on there.

 

Regarding google rankings, I do that sort of thing (SEO) in my day job so if you need any hints/tips or anything, dont hesitate to ask

[dch1950 37 1 Cars]

Fair enough on the ebay front, it can be expensive, but i was thinking along the lines of just listing one product, that sells well, then adding a link to your website on there.

 

Regarding google rankings, I do that sort of thing (SEO) in my day job so if you need any hints/tips or anything, dont hesitate to ask

 

I did't think you could just use Ebay listings to put a direct link to your own shop. Not without paying seller fees any way. Are you saying there's a way round that ?

As for search engine rankings - any help on that would be gratefully received.

regards

Dave

[johnnyboy666 195 1 Cars]

You'd still have to pay seller fee's, I meant just sell one product, ok there would be a little expense but the customers who would then be forwarded onto your website would probably be worth it.

As for the search rankings, send me a pm with what you want to acheive, and I'll let you know what I can do for you

[dch1950 37 1 Cars]

You'd still have to pay seller fee's, I meant just sell one product, ok there would be a little expense but the customers who would then be forwarded onto your website would probably be worth it.

As for the search rankings, send me a pm with what you want to acheive, and I'll let you know what I can do for you

 

Hi John,

I know what you meant.

regards

Dave

[mhyphenl 10 1 Cars]

No point in ignoring a market though and ebay is a very big one! Just add the fees to the price, people who have the nouse to find your site get a better deal but people just browsing ebay will pay a slight premium, about 15% should do it, also listing and re listing few items on ebay is very easy, Paypal is relatively secure and believe me, selling with your own card facilities is not without significant fees. I run a fairly sucessfull online shop ( www.rattleanddrum.com ) and the transaction costs do add up!

[dch1950 37 1 Cars]

No point in ignoring a market though and ebay is a very big one! Just add the fees to the price, people who have the nouse to find your site get a better deal but people just browsing ebay will pay a slight premium, about 15% should do it, also listing and re listing few items on ebay is very easy, Paypal is relatively secure and believe me, selling with your own card facilities is not without significant fees. I run a fairly sucessfull online shop ( www.rattleanddrum.com ) and the transaction costs do add up!

 

Hi - it's the inefficiencies implicit in the the search that is niggling me. I did my research last year prior to setting up my cart and related payment systems.

I agree on your comments about card services in general. As for Ebay itself - it is a large market agreed - my product is not going to be attracting the casual ebay cruiser though. In general (I think) that my customers are going to first level 205 GTi owners, they are likely to do their own maintenance and they also wish to take care of their cars. More interestingly though from a personal point of view - I know how many times my first site of choice is Amazon, whereas maybe 10 years ago it would have been a specialist site, especially when I was looking for that new mobo, or a GT graphics card. It is not quite so clear cut now.

The best level equivalent I can see is stewart's BBM site - indeed we have had an initial chat about cross linking products.

I think I will probably get on to him and have a chat about the relative effectiveness of selling outlets, if he doesn't mind that is. We'll see.

thanx guys.

Dave

[GLPoomobile 958]

I have to say Dave, that I do think that you'd be potentially missing a lot of customers by not using eBay (as much as I bloody hate eBay ).

 

I'll raise two points on that subject:

 

1 - Even the the type of 205 owners that you've described are often guilty of not researching what is available for them. That's patently clear from this forum, with so many people constantly asking the same questions instead of doing a search. And how many members have bought goods at full price, because they didn't realise the seller was a forum discounter? How many people buy parts at inflate dprices becuase they are sold on eBay as "rare" or discontinued, when they could have just got it from the local Pug dealer? People are lazy, and eBay is an extremely convenient service for the buyer.

 

2 - Speaking personally, there has been many a time when I've been browsing 205 stuff on eBay and I've come across something I didn't even know existed, or just seen something at a good price and bought it because it might come in handy. I think you are assuming that your customers will hunt you out because they will be searching for a supplier of new covers and find you on the internet. Don't wait for them to come to you, let the world know you are here! I bet there will be loads of 205 owners who will one day be trawling eBay and will see your shop, and they'll be excited to discover that someone is selling good quality reproduction bolsters and covers. Gone will be the days of hunting scrap yards for the bolsters from a passnger seat to repair your drivers seat, or paying over the odds for worn and dirty half leathers.

 

You know it makes sense

 

By the way, I'm not sure if it's against the forum rules, but if it's OK I think you should have your web address in your signature. What is it again, I want to have a look at your site but I'm too lazy to search

Edited March 25, 2011 by GLPoomobile

[dch1950 37 1 Cars]

Hi everyone,

At no time have I said I am going to ignore Ebay. If you (lazy?) people refer to my first post you will see a somewhat definitive phrase on the initial production numbers. These are small batches and given the actual physical process and the other commitments of my foam moulder, I don't know yet whether even that will be achievable. Bear in mind that I have 2 moulds at the moment - one for each side and thus I anticipate that these items will sell pretty quickly.

 

Now, next point, Don't take what I've said out of context, for my own part I would wish that my products sell to people on this forum and PSOOC who both seem to be a logical market. Clearly , if I could produce 100's of foams at the drop of a hat then I would have no qualms at seeking out every one possible , taking their money and having a nice® life. Reality is, as I don't know what is a realistic batch production level then the very first market will be your good selves (lazy or not!).

 

I am well aware of the foibles of forum users and the weakness of this form of thread based "conversation" is that it isn't one, it's more like people walking past you when you are having a conversation, overhearing a snippet, and then commenting as they walk away.

 

My well known propensity for detail carries me forward in these cases and whilst I thank you all for your input, I can only judge what will actually happen when i have the stats to look at. No marketing strategy is ever cast in concrete and this one is no exception. I sincerely hope that things will take off but I am only one person doing pretty well everything at the moment.

I do however, remain a dedicated PUG nut and am happy to be associated with my fellow nuts on this forum.

my best and sincere regards

Dave

[GSXR_J 0]

Great thread and defintely intreasted in the moulds when you have them up and running!

[dch1950 37 1 Cars]

Hi everyone,

just got back from Coventry and have the first pair of production bolsters here in my hands. I have placed my first "proper" order and these will be collected and ready for sale next week. Production of a batch taking 1 working day so I am informed.

I am also having the thigh bolster cover patterns revised (professionally) prior to the pre-production phase of product #2 - the cloth bolster covers to go with these little beauties. I am hoping that they will follow on in about 7 to 10 days time.

Things are picking up pace now and any spare time I have had is disappearing raidly.

Hope you like these.

best regards

Dave

 

 

 

PS - GSX these are foam casts - I am keeping the moulds

Edited March 31, 2011 by dch1950

[dch1950 37 1 Cars]

Hi all,

in anticipation of you all wanting to fit my new bolster foam I thought it might be useful to lift a couple of piccys from my "Bolster refurbishment manual" (available for free download (.pdf file) from my website).This is just to show where the best cut line is when you chop the old one out. If you've already done it and not cut so as to leave the "holes where the chain links go through to fix underneath, then you will need to cut some padding strips to run between the bolster and the seat cushion.

The last thing I want is people saying "they don't fit properly....!".

regards

Dave

Note for GLP - if you Google "205 GTi seat covers" I pop up third in the list of results.Also rules don't permit me to put my web address in my sig.

 

 

 

 

Edited April 1, 2011 by dch1950

[dch1950 37 1 Cars]

Hi everyone,

progress and status update !

First batch of 50 commenced production this Monday. Unfortunately the lids for the pattern inserts were not up to the job and split.

Bugger.

Have them with me as we speak in order to re-mount them on some more solid timber and get them back to Coventry by Friday.

I am currently doing a deal with a "pro" trimmer sewing machinist to do my my bolster covers ( all flavours). If this goes as expected then products #2 and 3 wll be close behind the bolster foams.

I am not sleeping very well at the moment as my mind is running at about x thousand miles per hour.

Keep the faith -

regards

Dave

[dch1950 37 1 Cars]

Hi everyone,

I finally got production of the bolster foam re-started earlier this week. New lids for the pattern inserts had to be fitted.

Yesterday saw me visting my sewing machinist to get the price and pre-production wrinkles sorted product #2 - the bolster cover repair kits, this went well and I got back home last night well pleased with current progress.

Today I'm picking up the first batch of foams and once I get my web site shop sorted out I will put these on sale there as I promised.

(I say promised - but the pre-production problems have sent me mental and even I was beginning to wonder when I'd actually stop talking about it and actually doing it !) No matter I've got there - I feel rather underwhelmed by it mind, it probably hasn't sunk in yet.

With final pattern verificiation being done in the next few days, the bolster cover kits will be on sale in about 7-10 days time.

Also been looking at a great new insert fabric which is a great Alcantara substitute and once I get some samples I'll probably give it a try. I have also still been trying to find an EU based supplier/manufacturer for my Quartet replacement fabric, contacting the Textile institute, major car trim manufacturers and even small hand weavers. The small weavers are interested but can't supply in quantity and the big companies won't even consider anything under 10,000 metres (it's to do with the size of the dye tanks apparently!) so no progress on that front yet. The textile institute just amused me no end - they spent 2 weeks finding one of their "members" who could possibly help me, he then "graciously did free consultancy which resulted in the great conclusion that there weren't any companies left in the UK capable of doing this type /scale of work. Great stuff hey - makes you proud to be British -....almost.

As the hawk eyed will spot I 'm typing this in at around 5 am this morning - couldn't sleep again.

regards to you all.

Dave

PS I will give preference to bolster purchasers if they register their interest via my site. Seems the fairest way to allocate them I think.

D

Edited April 13, 2011 by dch1950

[dch1950 37 1 Cars]

Hi everyone,

I checked my project diary/workbook yesterday and it's 12 months to the day that I started this project/firm so I feel it is relevant to state what I have actually both found out, and achieved. The dream of reproducing the Peugeot insert fabric called "Quartet" is indeed, just that. I have had no success whatsoever in this area. Nobody is interested. Appalling but true I'm afraid. I will not, therefore, carry on with that product line.

 

If anyone else is ready to take the baton (or even perhaps a forum led initiative) then the only glimmer of hope is a firm in the states called SMSautofabrics (web site here: SMS auto fabrics site ). I was in touch with them in the New year and they said they could reproduce the fabric and that they wanted 100 yard order (minimum) at a cost FOB, of $35 per yard. This was sold unseen though and the cost was more than I could reasonably undertake plus the additional costs of importing it i.e. Vat,Import duty, shipping, storage etc,etc,etc). In their favour though they did say it could be done. Mind the number of times I've heard that one.....!

 

The black cloth I found to replace the 1.6 cloth bolsters has also hit problems. The Italian firm that makes it , well they don't any more so I have 5 metres in stock and that's it. So 1.6 repro seat covers along with the Rallye are now dead in the water unless I can find a new supplier. This may well be possible - but it's going to take time.

 

All this sounds a bit negative - so here's the good news - Drum Roll. The thigh bolster seat foams are in production and I have the first batch in my hands as we speak. I need to set up a few more things on my shopping cart before selling through my site but I do have them and I am taking orders now.This is first come first served.

 

My seat covers will center around a completely new seat cover design. This will be leather bolsters, with Alcantara inserts. A GTi logo embroidered into the the squab top section.Colours will be Black, or Dark Grey.

I will also be making leather or Alcantara front seat bolster covers for use with your existing insert material.

Thanks for your continued interest in my project.

best regards

Dave

Edited April 14, 2011 by dch1950

[cRaig 265 1 Cars]

Sorry to hear you havent had any luck after a year of trying to source/commision new material. I guess if you cant do it, its very unlikely anyone else will suceed, given the ammount of effort you have put in!

[dch1950 37 1 Cars]

Sorry to hear you havent had any luck after a year of trying to source/commision new material. I guess if you cant do it, its very unlikely anyone else will suceed, given the ammount of effort you have put in!

 

It's only the one fabric and I personally can't afford anymore time or money to pursue it. SMS is a possibility but not for me. My business isn't just about making genuine reproduction seats for the 1.6., I was as pissed off off as you but business is business.

regards

Dave

PS the french forum are obsessed with getting this material, and I don't think the "Club de France" were very happy when I gave truth to the (white) lie about "we've got some Quartet fabric". Still we'll see what happens

D

Edited April 14, 2011 by dch1950

[dch1950 37 1 Cars]

Hi everyone,

I have spent most of today sorting out my web shop. This may sound trivial but its taken me all day sorting out the finer details of buying on-line.

A day late I know - but if you want to buy my bolsters - they are there so go for it while they last.

regards

Dave

Edited April 16, 2011 by dch1950

[dch1950 37 1 Cars]

Morning eveyone,

I'm somewhat relieved now that I have a working web shop. That was a frantic 24 hours I can tell you. On Friday last while at the foam moulding shop I also picked up the seat patterns that I had had reviewed/amended by a pro trim designer and pattern cutter. He said for the most part my basic outlines were OK but that there were details of the piece joining seams and fitting nicks that I wouldn't have known about as a novice trimmer. The new patterns go to my machinist next week and bolster (B09 cloth) productioin will commence.

These new patterns are a significant step forward for me as the fit is the defining part of the GTi seats, whatever the chosen material is.

When the inserts (the easy bit to sew) are also ready then we are well on the way to prouct #3 being ready - the full seats in hide/alacantara. Weather outside looks nice today so a BBQ may well be on the cards.

regards

Dave

Edited April 17, 2011 by dch1950

[dch1950 37 1 Cars]

My heartiest thanx and congrats to Paulmac19 - you were my first

Dave

[Paulmac19 4]

Well I must say a mega thanks to Dave

Credit where credit is due the product i received is fantastic, and i feel very proud to have been the first of Daves many customers.

His web shop is open for business and he has a stock of bolsters ready for sale.

 

A true inspiration to us all what can be achieved when someone is so committed.

 

Remembering that a decent interior is what many of our cars are lacking, this could spell the end of all the angled photos that never show the drivers bolsters

 

I am possibly going to tackle the swap of the bolster this week so i will keep everyone posted on how that goes..

Sad as i am Dave i just cant stop looking at the new one you sent

Edited April 24, 2011 by Paulmac19

[dch1950 37 1 Cars]

Thank you Paul for your kind appreciation. It's been a busy few days I can tell you.

Just to show my appreciation I have put some fitting notes together this evening and if you would like to use (and hopfully request some changes to it as well) when you try your re-fit I'd be grateful

regards

Dave

 

Edited April 24, 2011 by dch1950

[Eliganza 2]

Superb, I will most probably invest later in the year when I tackle some cosmetic issues!