Plywood seat base

[Flaggo60]

This may seem like an odd opinion, but I am thinking of making a new cafe replacement seat for my 650G out of plywood. I thought about making it out of fiberglass, and realized I'd have to build a mold which I determined would be layered plywood which I could then shape on a sander to the desired form. Then, it hit me, why go any farther? The plywood is light, the seat comes off for winter storage anyway, I don't ride in the rain voluntarily anymore, etc, etc....

What do you think? I'm a lot better with wood than fiberglass or metal.

 

[STANDIGGITY]

But one that's already been made and mod it to your bike. if you're looking for the cafe look, it's out there, you just have to make it fit the bike.

Fiberglass Cafe Style Seat

 

[tomo]

When I chopped my 750 a few years back, I used an old aluminium road sign. The metal was about 4mm thick, easy to cut & bend. Trouble now is that they have started to use plastic over here, so the metal ones are harder to get.

 

[Dead Boy]

I used 3/4 inch MDF for the base of my cafe seat. I then covered it in a few layers of fiberglass resin. It's been over a year with no cracks. She's seen rain and nearly snow.

The plywood would probably work just as well. I would definitely cover it in resin just in case you go down so it (hopefully) doesn't splinter. That's why I went with MDF over plywood. The MDF will probably just turn into a powdery substance, the plywood could splinter and I'd rather not experience splinters in my arse.

 

[80GS750]

i usuallyl use cardboard to get my shape, then i glass over it and make a solid piece out of it.

 

[skidMarkNZ]

What do you think? I'm a lot better with wood than fiberglass or metal.

I think you are amish.

 

[gsryder]

I am currently making a seat for my 81 GS750.
I used composite lumber. (mainly used for decks and porches)
Composite lumber is very strong yet easy to cut, sand, screw, and shape.
Composite lumber is also weather proof guaranteed for something like 20 years I think.
It is a little pricey I paid around $35.00 dollars for a twelve footer. (couldn't get it any shorter in the width I needed)

This has not been tested yet but in theory.....................

 

[gsryder]

Here are a few pics

The pic of the bottom shows where I will be relocating the battery.

 

[gsryder]

Well that didnt seem to work. Lets try this.

 

[gsryder]

And here is how it started

 

[spyug]

Just wanted to inject a word of caution for all folks thinking of building a custom seat. Whatever you make it from, insure that you make a firm but substantial seat cushion as you can injure yourself with these "plank" seats.

Three years ago I built the XS650 tracker with a fiberglass over foam seat form and rubber/foam cushion.

I only rode the bike for a total of less than 300 km. in the fall of the year. Over the early Winter I had a severe & debilitating left leg injury which turned out to be a pinched and compressed Sciatic nerve. Pain so bad I needed morphine shots to control it. The Sciatic nerve runs out of the spine and down the legs to the toes. In most people the nerve is protected by the buttock muscles and runs through them. In some folks like me it runs outside of these muscles closer to the surface. Sitting on a hard surface can put extreme pressure on these nerve roots causing the aforementioned extreme and lasting pain and weakness in the leg and foot.

Close on 2 full years later and I still suffer. The latest episode began about 8 to 10 weeks ago and I haven't been able to ride since. Fingers crossed for a trial run this weekend.

Don't want to put anyone off, just wanted to pass on some more info.

Ride safe.
Spyug.

 

[OhioEric]

Hemmaroid sufferers also dislike plank seats. :-k ...not that I would know...

what the hell, cant you use a couple of layers of a mouse pad or other closed cell foam like a gardening kneeler?

my ass hurts just lookin' at those....

 

[spyug]

Good point OE. I would think if you have any back, leg or buttock problem you would want to stay away from these seats.

I did try 6 or 7 seat pad designs before I came up with the latest which actually works fairly well and you mentioned it. The garden kneeler pad.

It is a closed cell foam about 1.5 inches thick. Two layers seems to do the trick. Firm but spongy enough to cut the shock of any bumps.

Give that a try.

Cheers,
Spyug

 

[Flaggo60]

I think you are amish.

I do ride the only horse-drawn black Suzuki in Eastern Ontario... and bless you for noticing.

 

[gsryder]

Its funny that you mention the garden kneeler pads because that is what I am riding on know every day. That was the prototype material that I think works fairly well and is what is going on my seat. The pictures are just of the seat frame there will be a stainless steel seat pan with the padding and cover attached to it.

 

[Flaggo60]

Personally I could use a plank-type seat, as they are commercially available, but I wanted something that integrates the rear cowling of the GS650G into the design-also, I too fear back and butt injury with the nominal flat pads that seem to be part of the cafe design. I was thinking more along the lines of a samll one-up seat that BMW sold years ago with its R100RS bike, a large well-upholstered single seat (I don't ride two-up).

See sketch here:

 

[Flaggo60]

Sorry, thats "small one-up seat", not "samll one-up seat".

 

[Flaggo60]

i usuallyl use cardboard to get my shape, then i glass over it and make a solid piece out of it.

That's an interesting idea.

 

[skidMarkNZ]

I do ride the only horse-drawn black Suzuki in Eastern Ontario... and bless you for noticing.

Isn't that how all harleys get anywhere?

 

[rudy]

I know a lot of guys use plywood, but I'd just as soon stay away from it. It's wood. Nothing against it, but I don't think it belongs on a bike. And there's the whole issue about weight and rotting. Plywood is heavy if you get stuff that's sufficiently strong, and even more so if you start making layers of it, then coat with resin and paint.

If you're going through all the trouble, make a fiberglass seat. Not much more work, and it's gonna turn out better. I even put a bit of aluminum sheet in my cafe seat to make it more rigid. If you'd like the whole process, let me know. I used the closed cell kneeling pad foam as well. Works great, and cheap as chips.

There's nothing like a seat you've made to exactly fit your bike, not just ordered off ebay for a universally crappy fit.


Made a pink foam buck first, covered with paper mache' to make a cheap reverse mold.

Mounting studs are threaded through the aluminum sheet.

Total cost with paint and supplies, about $100.

Full custom LED tail lights baby! You won't find these on ebay.