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[thumcom]

I'm prepping to refoam the seats on a '65 Impala and hoping to benefit from others experience. Instead of using buns I'd like to build up using sheet foam. Density will be 2.8 for longevity but foam weights are my sticking point. Some are suggesting extremes of a very heavy foam (100#) for the base and very light (12#) for the backs. In addition I'm hearing thickness from 1" max total to 2" nominal.

The original foam is so far gone it's impossible to confidently gauge the factory weights or thickness. Would probably be difficult anyhow considering it was most likely poured/molded latex. The rear seat back was also 100% stitched cotton batting which I'd prefer to replace with foam. I'll be using polyester batting elsewhere when appropriate.

My thinking is the following:
Bucket seat bottom - Heavy denim decking / 3/8" rebond foam / 1" 70# foam sheet / Bolsters built up as required
Bucket seat backs - Heavy denim decking / 1.5" 50# foam sheet / Bolsters built up as required
Rear bench seat bottom - Heavy denim decking / 3/8" rebond foam / 1" 70# foam sheet
Rear bench seat back - Heavy denim decking / 1.5" 35# foam sheet

I was looking to make the seats a little firmer than the extremely soft norm of the 60's style. With that in mind I added one additional spring wire across each seat bottoms to tie the ziggers.

Been putting this project off for far too long so any and all suggestions most welcomed.

[John]

Hey @thumcom! Welcome to the forum!!
You plan for foam choices looks solid. One thing I will say though is that if you are looking to prevent the soft norm of 60s style... This is caused by the spring seat structure. You can put any density and it will still be soft from the springs. The bars across the middle will help for sure but it wont make it firm like a solid foam seat.

This post might help you as well. viewtopic.php?f=8&t=416&p=4151&hilit=ch ... foam#p4151

[thumcom]

Great info there John, much appreciated it...and the welcome!

The heads-up regarding seat suspension being the driving factor in overall firmness is good info and makes 100% sense. I can understand how a firmer foam will be more so only "skin deep". Thankfully my intention is not to totally remove the original character of these seats so hopefully my modest mod (single crossbar) will prove the sweet spot.

The link you referenced has quite useful info. The bit I need to keep rereading is "...choosing foam doesn't have to be as complicated as people make it."!

Now, if I may tap your professional opinion just a bit deeper...
You offer my "choices look solid" and that's a relief. I'm still unsure about the following -- Whether or not to add rebond foam to the seat backs (not just bottoms)? When using OEM style seat covers might it be better to opt for 1.5" or 2" overall foam thickness? -- No more questions after this. I order foam and get it done!

Thanks again for freely offering your expertise. After perusing this forum it's very easy to appreciate your insights.

-Ej

[John]

You very welcome thumcom. Glad it was helpfull.
Personally I dont use rebond foam at all just regular upholstery foam. There is no reason you cant use rebond. Rebond is pretty firm so that should help you. The most important thing is to put down the layer of denim over the springs. Otherwise the springs will eat the foam up. I actually use discount Black vinyl but denim works fine. Just dont use the orginal style burlap unless you enjoy vacuuming your carpet every time you sit in the seat. LOL

Ask as many questions as you want. I helps grow the forum.

[BigRig]

@thumcom, If you had a foam manufacture close you should really go in and talk to them. It is good to know the various types of foams for different application and there are a variety. I buy a very solid upholstery seating foam 1/2 that is not as stiff as rebond but much more solid than some 1/2 foams. This is a custom order product I requested.

[thumcom]

Appreciate the replies!

I'm a little late replying as tonsillitis took me down for the better part of the last week, just now feeling 100% again.

@BigRed
I can find no local upholstery supply that stocks foam (not even samples). I've even offered to pay for knowledge from a couple local auto upholstery shops regarding foam and while they say they'd be happy to suggest, unfortunately they can't, they only use prefab buns. In the past I spoke with a number of online supply shops and foam retailers but as I noted in my OP their opinions and suggestions on foam weight ran the full spectrum of weights.

Having decked with 20 oz. denim and laying down the single layer of 5/16" rebond I'm pretty satisfied so far. With that done it looks like I'll be sourcing 1" 2870 for the bases and 1" 2850 for the backs. Will also pick up 1/2" 2835 to use as a topper for those if the covers can deal with a near 2" foam total (probably should include the scrim/sew foam in total).

Will be ordering foam tomorrow so, barring any last minute words of wisdom, the dirty deed will be done.

[John]

@thumcom Sign up at Albrights supply and they will send you foam samples and fabric samples

[thumcom]

John, appreciate the heads-up regarding Albright's!

I had already ordered my foam elsewhere but looking through their catalog is promising especially if I decide to make use of your excellent door and kick panel carpeting tutorial. These carpet pieces, along with bottom 1/4 of door panel board, definitely require replacement. Unfortunately panel board seems to usually require high minimum quantities (5-10/pc) along with steep shipping rates. This has me looking for locally sourced 3/32" (or so) waterproof alternatives.

I'll be sure to post some pictures of the seats restoration process.

[John]

Glad it helped! I would recommend using 1/8" ABS or PVC foam board. You should be able to source both locally for reasonable price.