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Old 10-24-2010, 07:28 PM   #1
davevv OP
One more old rider
Joined: Aug 2006
Location: Just north of Dallas
Oddometer: 2,368
'74 DT360--seat rebuild.

So, I bought this old 360 Enduro a few weeks ago. Only has 2744 miles on it, but it has been sitting in a shed in the Texas heat for about 20 years. It starts and runs, but rarely gets below 3-4k rpm, so I'm thinking the crank seals are probably toast and it's sucking air. I also intend to rebuild the carb just on general principle. Tank is squeaky clean (even shiny inside) but the petcock leaks. So, I have a few things to do, but none of the mechanical parts have arrived yet.

However, the seat cover had a hole in it and the foam has begun to harden and disintegrate. New molded foam is unobtanium, but I did find a reproduction seat cover and had it on hand so I decided to rebuild the seat today.

This is the offending foam. Top side looks pretty good, but the bottom is crumbly.

Cleaned up the pan, which was pretty rusty under the foam, but still solid. Primed it all and painted the bottom side.

A can of spray adhesive and this (closed cell foam and pretty dense)

made a new seat in a few easy steps.

First layer filled in the depressions in the pan.

Next layer filled in a few more depressions and smoothed things out some.

Then add more layers and trim with electric carving knife to get to this.

I used an angle grinder with 100grit sandpaper to do the final shaping and smoothing, but forgot to take a picture of it. After that, some people put a solid piece of 1/4" foam over the whole thing to smooth it out, but I didn't bother with it.

Installed new seat cover and, voila!

It ain't perfect, but much better than what I had. And by the way, that exercise mat makes a very firm seat.
"Fast is fine, but accuracy is everything"--Wyatt Earp
'13 Yamaha Super Tenere.
'04 Sportster XL1200R

davevv screwed with this post 10-24-2010 at 07:45 PM
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Old 10-25-2010, 06:57 AM   #2
Gnarly Adventurer
DoubleBit's Avatar
Joined: Apr 2008
Location: Applegate, Nor Cal
Oddometer: 305
Nice lookin' old yami!
Loved those old two strokes, learned to ride on an early 70's 175 back in the 70's.
Ja, I prolly would've used a softer material for the top half of the padding.
Butt it's your bike and it sure looks better than duct tape and an old tee shirt!
Current rides: DR650, CT90.

Riding whatever runs, wherever I want.
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