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Old 09-27-2011, 09:31 AM   #34
Airhead Wrangler
Adios Mexico
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Joined: Mar 2008
Location: Back in Seattle, FINALLY
Oddometer: 6,569
In my limited seat carving experience, I've had pretty good success with an electric carving knife (yes, the kind that some people have in their kitchen) for the bigger cuts and an angle grinder with a flap wheel or the finer shaping operations. Get ready to make a mess. The 8 lb rebond foam is what most pro saddle makers use if they need to add material. It feels a little hard, but it softens up with use. Find the right spray adhesive for the job and you'll be good to go. Usually seat shops get the final shape "close enough" and then wrap the entire thing in a 1/2" sheet of softer foam to take up the small surface imperfections.
R80ST Gets The HPN Treatment
Seattle to TDF on an airhead

Current rides: HPN #834, '93 R100GSPD "red rocket", '73 R75/5 Toaster mongrel, '80 Ducati Pantah 500SL, '92 DR350, '67 Honda SS50, '80 Honda Chaly.
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