ShopTalk Interior HI-LO CUSHION HOW-TO BASIC PILOT SEAT WITH A FIRM BASE Start with a marine-quality base material in good condition. Your cover will need to fit tightly and will be attached to the base with stainless steel staples. Common base options include Sintra® PVC, King StarBoard® High-Density Polyethylene and marine plywood. All of these will withstand the challenging marine environment. Your exterior material should be marine-grade vinyl or fabric with excellent UV protection and stain The original foam on this pilot seat had deteriorated. resistance. Consider the following items during fabrication: * Pattern the area for contours, with interior staple bands length, width and band length sewn next to the center and height of the seat. seam lines. Include single * The base material should be 1/2 inch to 5/8 inch thick with smooth edges on all sides. along the sidebands. * Glue the center seat foam to the base. Staple interior bands evaporation, approximately two fore to aft at divisions. * Indicate hi-lo areas on the base material. These will be your staple lines to achieve a hi-lo cushion. * Prep the marine foam and * Glue the side seat foam to the base and check the fit. * Confirm sideband fit and taper the edge that will be sewn to the top of the seat. This band will cut it slightly larger than narrow as it crosses the center the base sections. We use panel. It will be higher as it firm-density foam for seats transitions along the hi sides and and a medium-firm density seam joints at the center back. foam for the back areas. * Consider using a 1/2-inch to 1-inch topper in a layer of Dacron® to give it a soft loft. Cut new marine foam slightly larger than the base sections. or double topstitching Include air holes for moisture to four for a 16-inch section. The original pilot seat base with air holes. The new cover is stapled along the side bottoms to the base. * Assemble the upper sections if needed. Determine the final * Prep the pattern sections from the foam contours. Cut new material with seam allowances * Staple the cover along the side bottoms to the base. * Add piping around the seat edges for a finished look. * Prep and staple the back-snap flap to secure the cushion to the underside of the pilot seat. for the tops, sides and a back flap, if required, to secure the seat via snaps on the base. DETAILS FOR A TWO-PERSON SEAT: Join the three vertical panels with interior staple flaps. * Join the horizontal line with an interior staple flap. This two-person Sport Fisherman 44-foot aft seat is attractive and comfortable. * Staple the horizontal flap followed by the vertical flaps. 46 Marine Fabricator | March/April 2020 0320MF_40-CV4.indd 46 2/19/20 11:47 AM