How To: Making new seat backs for under $20

[jawn101]

Someone requested this be posted, so here it is :) The process is pretty simple:

1. Remove your old seatback from the seat and remove the leather skin. Just carefully pop out all the staples.

http://dmctalk.org/attachment.php?attachmentid=22662&d=1382451955

http://dmctalk.org/attachment.php?attachmentid=22663&d=1382451956

2. Trace the old back onto some new Masonite board. I got 1/4" and it has seemed very sturdy. My old board was in two pieces, so I had to clamp them down to get things straight and the correct size.

http://dmctalk.org/attachment.php?attachmentid=22664&d=1382451956

http://dmctalk.org/attachment.php?attachmentid=22665&d=1382451957

3. Cut out the pattern and sand it. You don't want any sharp edges or burrs as they may wear through the leather skin. Make sure that you keep the large cutout in the center, as it provides room for the springs to flex when you get in and out of the seat.

http://dmctalk.org/attachment.php?attachmentid=22667&d=1382451959

http://dmctalk.org/attachment.php?attachmentid=22666&d=1382451958

4. Transfer the side and top brackets to the new board and rivet them in place. I chose to move mine "out" towards the edges of the frame by about 1mm in the hopes that it would grip the seat frame a little better. The gamble paid off, but your mileage may vary on this.

http://dmctalk.org/attachment.php?attachmentid=22668&d=1382451960

http://dmctalk.org/attachment.php?attachmentid=22669&d=1382451961

5. Clean the leather skin very well, inside and out. It will likely be full of disintegrated foam dust, maybe some mold, who knows. Now's your chance to get it antiseptic without risking damage to the backer board.

6. Staple the skin in place around the new backer board. I think it is wise to re-use the existing staple holes whenever possible to preserve the integrity of the material. *BE SURE* that you get staples that are only as deep as required, so that you don't puncture the leather. I got the shortest staple-gun staples that my Lowe's carried, and I held a thin strip of leftover masonite between the backer board and the skin as I did each staple to make sure that they didn't go through to the other side.

7. Screw the new board into place and pop the clips in to the frame. If you've done it all correctly, the seat back should stay in place for years to come! I did mine about 24 months ago and they have not fallen out a single time since.

http://dmctalk.org/attachment.php?attachmentid=22670&d=1382451962

http://dmctalk.org/attachment.php?attachmentid=22671&d=1382451963

http://dmctalk.org/attachment.php?attachmentid=22672&d=1382451963

You're done!

[wrkey]

Awesome! You da man!

[DavidProehl]

Excellent instructions, and looks great! I need to tackle this job, looks easy enough.

[DavidProehl]

So I'm mostly through this job, just need to staple the leather back on. The factory staples are 3/8" wide by 3/16 tall and were slightly coming through the other end of the board. I've replaced my board with one of identical thickness, so I don't want to use a longer staple. The shortest staple I can find (http://www.lowes.com/pd_64681-412-504IP_4294865658__?productId=1095499&Ns=p_product_qty_sales_dollar|1&pl=1&currentURL=%3FNs%3Dp_product_qty_sales_dollar%7C1&facetInfo=)is 1/4" (1/8" wider) by 6mm (1.2 mm taller). Did you have better luck finding shorter staples that match existing holes? I'm likely going to have to find 1mm of filler to staple through so I don't puncture my leather.

[Spittybug]

Anyone tried gluing rather than stapling?

[DavidProehl]

Anyone tried gluing rather than stapling?

Apparently the answer is yes: http://dmctalk.org/showthread.php?5761-New-Aluminum-Seatbacks&p=86995&viewfull=1#post86995

I didn't realize there used to be foam under there. I'll have to find some. I bet that would add the thickness I need.