Bolster Cover(s) Material

[dch1950 37 1 Cars]

Hello everyone,

I had something of a revelation today when I managed to get over the visualisation problem I was having. Seeing the individual pieces laid out was puzzling me as to how I could actually sew them together. I know this seems a bit daft but my skill base with sewing machines is about 2 weeks and I couldn't get past the 2-D block in my head. I remembered that my Mom and my Nan often used to make their own clothes and I was racking my memory to remember how they used to do the "mock up" and then fittings of various new patterns.

Then the blinding flash - they were always tacking stuff up before final sewing to check on the fit of clothes. Tacking being done with a running stitch and I believe is called "basting" I call them tailors tacks and once I got into the swing of tacking the bits together it started to come together (literally!). I got a backrest and a thigh cover roughed up today.(see diary entry) and will move on to a final material version after machine sewing the "piece" hems of the denim versions.

The intial problem was thinking I could just pin the edges together and then machine them - Nooooo,Nooo,Noooo..

Tacking is the way. I was beginning to think hthat I'd made a giant mistake in thinking I could this - but the problem is now solved and the end product is getting closer

regards

Dave

PS - I can hear my Nan chuckling away and telling my Grandad "I told you he'd get eventually" - bless her.

D

[dch1950 37 1 Cars]

Hi everyone,

a slightly frustrating week but progress has been made. I have made a third set of adjustments to (hopefully) finalise the patterns and have written up the assembly notes for the thigh and backrest bolster covers (these will be published in the diary along with the the naming conventions I have drawn up. Just in case you thought this project was "hot air" here's a couple of snaps of the practice denim versions - as shown they have been tacked together very loosely (no final machine stitching in place here) so don't judge too severely.

 

 

 

and

 

 

 

My main concern has been to get the "notch" seam right on both covers, and of course to keep my seams straight !

I am cutting out a first (final) set today and will machine them tomorrow hopefully.More pictures to follow provided I don't cock them up.

Enjoy

Dave

[jimistdt 1]

Great work here Dean, enjoying this thread. Really respecting the amount of time effort you are putting into it!!

[dch1950 37 1 Cars]

Great work here Dean, enjoying this thread. Really respecting the amount of time effort you are putting into it!!

who the F***k's Dean ?

regards

Dave

[jimistdt 1]

Sorry Dave. Obviously I didn't read that bit

[dch1950 37 1 Cars]

Hi All,

I have moved back to bolster repair - you thought I'd forgotten didn't you. Did my third repair today, glued up up the closed splits, and also edge cracks, then as per usual cut out a block section with the hessian insert intact. The cut a block out out of my repair foam of the correct length (and 60mm wide) and then cut an offset slot into it. A liberal coating of the L107 adhesive and then I use cocktail sticks and duck tape to secure and straighten the foam (if needed). see this piccy:

 

 

I also started on a bolster which has split and opened up like a book. I glued the obvious bits together and will wait for the glue to set. This is a different type repair and I'm thinking that making good with small strips of foam built up in layers may well work, or even crumb up some foam mix it up with some adhesive and spread it into the damaged section to make up the profile. We'll see on that one.

 

 

 

I am looking to digitise the patterns, and as is usual with these things it is a little involved in terms of s/w processes.

Scan smaller parts to.pdf, or possibly use a program I've found called "scan2cad" which does exactly what it says - and we end up with a dxf/dwg file which can edited by autocad. The larger patterns will have to scanned in parts (unless I can find a copier shop with a decent drum or large flat bed scanner to do it one piece. Another nice little program is "Autodesk Design review" which will let you import DWG files and tile print it - normally a feature only in s/w like Adobe Acrobat (for pdf's) and this is free issue. - I like it.

I have to go through this rigmarole as the digital version of the patterns must print out "correct size", unlike Jpgs which size up or down willy-nilly.

I'm getting there - albeit slowly.

regards

Dave

[dch1950 37 1 Cars]

Hi all,

been a bit distracted today - MOT time - failed due to a busted light switch (inoperative main beam),bulbs were OK, so it's a bit of a weird one as everything ckecked out Ok when I did a run through to make sure !"£, that along with a split rack gaiter for good measure. - ah well easily fixed - just a nuisance.

Any way I was going to cut a set of covers from my new material today but I didn't get round to it. Here is a picture of the part layout, a seats worth of bolster covers will fit in a half linear metre, so my earlier estimate of a linear metre for 2 seats seems to be holding good.

 

 

 

regards

Dave

[dch1950 37 1 Cars]

Morning everyone,

I have been wondering about how to surface finish the new pieces of foam that I have glueing into place on the thigh bolsters. The guy at Classic Motors says he uses a electric "finger file" -(essentially a mini belt sander with a no.80 grit belt). I looked at these but they're a bit expensive and not being one to splash the cash unless I really have to I decided to try to obtain a similar finish with some drum sanders (the type that just fit into a power drill). Ordered a kit of bits made by Silverline - a good mixture of different radius drums and a selection of sleeves. It arrived this morning and as it is such a nice day I gave it a whirl. I really should have popped the bolster on my jig - but I was in a rush to try it out.

Seems to work fine - little bit messy though. I will have to remember not to cut back too near to the final profile and then "linish" to a nice smooth finish.

Here's a piccy

 

 

 

regards

Dave

PS Booked in for my re-test today - should be OK unless they bust the switch again!

D

[dch1950 37 1 Cars]

Hi everyone,

What a cracking day - anyway I spent a hour getting the patterns cut out for a first "final" set and believe me if you have not done this before (as per yours truely) then be prepared for one or two C**k ups. Failing that get someone who is familiar with dressmaking etc to help you or you may well waste a bit of material. Got it sorted after a few "blue" moments though and here's a piccy for those following this thread.

 

 

 

The diary is updated and also has an appendix with my sewing and assembly conventions, these will used in the assembly notes in which I will assume you have read and are familiar with my notation.

Summers here guys. Enjoy it while ye may!

regards

Dave

[lemmingzappa 75 1 Cars]

[jeremy 71]

Roy Castle would be very proud of you now. Keep up the good work.

[dch1950 37 1 Cars]

Roy Castle would be very proud of you now. Keep up the good work.

Roy who?

Is this an Essex joke.

regards

Dave

[dch1950 37 1 Cars]

Hi everyone,

now that I am moving into the constructive part of this project (and hopefully towards production of covers) is anyone out there willing to take a set of my patterns (paper in this case) and run a parallel exercise in producing covers.

This would be useful in terms of verifying my assembly notes and patterns. Plese PM me if you would like to have a go and are willing to comment and send me feedback on the success (or failure) of the exercise.

regards

Dave

PS Jeremey - the only connection I could make with RoyCastle was recordbreakers, and the fact that he died of lung cancer induced by playing in too many smoky night clubs. - Soz

D

[SurGie 54]

Sorry Dave. Obviously I didn't read that bit

 

Not surprised with the lack of paragraphs on most of the posts.

 

Great work.

[dch1950 37 1 Cars]

Morning everyone,

The great stich up has started, albeit after a couple of false starts yesterday during which I had to adjust my method slightly to get the result I wanted. You may or may not be aware of the fact that each bolster cover comprises of 3 main pieces, 2 inner face and 1 outer face. The 2 inner face pieces are joined by an ordinary flat seam and then this piece is sewn to the outer face piece in one continuous compound curving seam. To do this straight off on the machine has been my downfall on a couple of occasions , hence the tailors hand tack method has evolved. Anyway here are a few snaps of the first ever set of bolster covers (backrest LH) produced by yours truly using my own patterns and material.

Drum roll please Maestro......

 

 

 

 

 

 

 

I think the material looks good although the lens doesn't really do it justice. This afternoon I will machine this cover and hopefully tack up a thigh bolster and machine that as well. This will mean I can further perfect my assembly notes.

regards

Dave

PS thanks for your kind support, this is to help us all.

D

[dch1950 37 1 Cars]

Hi everyone,

I wish I could report massive progress, and actually the backrest bolster covers are nearly there now. It's the thigh bolsters which have been driving me mad. Apart from the general thing about machinine sewing i.e smooth lines etc to avoid puckering (what a great word ! - sorry) it has been alignment of the three parts which has been causing the most problems. These few piccys will ilustrate the matter.

You sew it up inside out - of course.

 

 

doesn't look feasible really does it.

 

 

but by turning it in towards yourself as you tack it together

 

 

it does gradually, and then you turn it right side out and there you go.

 

The Notch definition looks better , but the main problem with this one (4th attempt) is that the seam alignment (down the notch) is off line a bit. But if you read my diary you'll see that inspiration arrived to save the day (and my sanity)

regards

Dave

[Pugleyrich 37 1 Cars]

Hi Dave,

It looks to be coming along nicely so far. Where is this diary you mention? I am sure you have posted a link in the thread somewhere but I can't find it!

[dch1950 37 1 Cars]

Hi Dave,

It looks to be coming along nicely so far. Where is this diary you mention? I am sure you have posted a link in the thread somewhere but I can't find it!

Hi,

it was in post #25 back in April. Here it is again though -

 

Upholstery project diary guest password is "dch1950"

 

It is a pdf for generality, and is updated every couple of days. Also more photos and other stuff.

It was recommended by a forum member (Andi) and it's free - great as a mailbox and when e-mail says no to your attachments.

regards

Dave

[Gentrix 2 1 Cars]

Hi Dave,

 

reading your diary, do I understand you correctly, that you will not reproduce the whole Seatcover but only repair the bolstersections on Seatcovers?

 

Because then I look at the center sections from seats that I have or had in the past, there wasn't one complete set without rips and tears in the middlesections.

 

And especially those green/black, blue/black or red/black chequered parts are impossible to come by as material.

 

I think a complete set of seatcovers in black - like the rallye seats would help a lot to convert ugly velours seats in sporty fresh seats.

 

And some frenchmen will pay you crazy money for Rally-Seat-Cover-Reproductions. (should have kept this quite)

 

Andi

[dch1950 37 1 Cars]

Hi Dave,

 

reading your diary, do I understand you correctly, that you will not reproduce the whole Seatcover but only repair the bolstersections on Seatcovers?

 

Because then I look at the center sections from seats that I have or had in the past, there wasn't one complete set without rips and tears in the middlesections.

 

And especially those green/black, blue/black or red/black chequered parts are impossible to come by as material.

 

I think a complete set of seatcovers in black - like the rallye seats would help a lot to convert ugly velours seats in sporty fresh seats.

 

And some frenchmen will pay you crazy money for Rally-Seat-Cover-Reproductions. (should have kept this quite)

 

Andi

Hi Andi,

I am currently working on the bolsters as they are trickiest part to make. I have several full sets of inserts in red and green - in good condition. The inserts themselves are easy to make from other materials - it's just straight line seaming.

Thus you may conclude that a full seat cover made from a single material is easy once the bolster(s) patterns are complete and verified. The choice of the the faux suede materials would bang the price up - see my earlier research into both the ribbed cloth in black , and the more expensive Alcantara etc.

For my own vehicle ( a cherry red) the inserts are fine and I will be using the material I found to replicate the original Peugeot (Delcar 2149). bolster covers. Nothing is set in stone yet and when I'm ready any material could be used.

What started me down this road was a silly quote of £200 a seat just to essentially patch mine up.

I want to get as many inserts as I can in order to refurbish sets to a good standard, or to at least give those people who want to do it themselves a way to achieve that,although if demand exists custom covers in alternate materials may well be viable. I have put a lot of effort into this project and I can see the benefits both to myself and others may well accrue from my actions. Why do you think I am being so pernickety about the detail of these covers. It is precisely because I want my replacments to look as good or better than the factory fitted ones. Alas the inserts will gradually become rarer, fact of life.

There is a lot more than just the bolster material involved here though, what with the the listings, both plastic and linen, the wire inserts, the velcro strips , the hog rings etc,etc,

I am also repairing busted bolster foam , and when I can find a supplier I may revive the idea of a moulded top section repair for the bolster themselves.

Plenty of things to keep me busy.

regards

Dave

PS Talking of the french - have you seen how they go on about their Pugs on their version of this forum.

D

[Gentrix 2 1 Cars]

...that's what I wanted to hear Dave

 

And yes - I know how the french rave about their GTIs - pedantic - is one word which springs in my mind.

 

And have you seen, that they already do a complete new seatfoam on this forum? It is quite expensive - but the optimal solution.

 

Though I think your diy solution of foam repairing is of more use for the common GTI driver who doesn't build a trailer-queen.

 

 

looking forward to your progress

 

 

andi

[dch1950 37 1 Cars]

...that's what I wanted to hear Dave

 

And yes - I know how the french rave about their GTIs - pedantic - is one word which springs in my mind.

 

And have you seen, that they already do a complete new seatfoam on this forum? It is quite expensive - but the optimal solution.

 

Though I think your diy solution of foam repairing is of more use for the common GTI driver who doesn't build a trailer-queen.

 

 

looking forward to your progress

 

 

andi

Hi Andi,

I think it's fair to say that the beauty of this forum is that the people on it not only love these great little cars but they drive them as well. They aren't as a rule obsessed by concours elegance and they are extremely practical and we also have some bloody good mech engs as well.

regards

Dave

[dch1950 37 1 Cars]

Hi all,

I have needed a break from bolster cover making for a bit so I switched to sub-project B , bolster repair and refurbishment. There seem to be 3 different types of repair emerging - 1 the chop out a section and replace it, 2 - just feed in the glue and use tape or cocktail sticks to hold it, and 3 - the intermediate repair.

I've been thinking about this one on and off for while now. The solution I am going to try is based on the bowl of foam crumbs pictured. I used a food processor to cut up chunks of foam (loads of static generated!) , I will then mix this in with some L107 as a binder and use it to fill up the smaller damaged areas of the bolster (as in Fig 41 of my diary). It should work provided the fumes don't get me first. I think bolster repair is a better route to follow (where possible) as this is a finite resource.

My real alternative therapy is in the garden at the moment (it's raining here though) - my rear beam taken off the 1.6 last September and could do with some tlc. I started just taking bits off it yesterday. A good mental diversion.

 

 

regards

Dave

[dch1950 37 1 Cars]

Hi everyone,

I have taken a few days break (terminal eyestrain was setting in) from sewing up the covers; refreshed and invorgorated I had another go at an LH thigh bolster. These things have been driving me mad as for some reason they are proving more difficult to get right than the equivalent backrest cover, which I am fairly happy with now and will move to a first "final fit" with. By that I mean getting the listings in and then joining it to a centre insert to get it onto the foam and properly stretched etc, up to now I have just been judging appearances by placing the covers on the foam.

These few picture show what I mean:

 

LH Backrest - nearly there now.

 

 

and LH thigh - getting better.

 

 

and both on together

 

 

This is taking a while to get right but It's got to be worth it. I have found a firm that will convert from tif format files to dwg (Autodesk internal CAD format). All I need now is to find a company with a large(ish) flatbed or drum scanner who can do a scan to print (to verify pattern sizes match the original) and then scan to Tif. It seems complicated but I'm sure this will work and will enable distribution of these patterns in a form that can be reproduced using an ordinary A4 printer (coupled with Autodesk Design Review software ( free distribution s/w). The lagest pieces being in the backrest and are about 27" long by 10" wide.

I would appeal to all my readers not to throw seat covers away - especially if the inserts are OK. Please consider letting me have them so that I can build up a stock of inserts which I can use in a "new for old" exchange.

No doubt some of you will want to do the job yourselves and I hope to be able to make the patterns available soon.

regards

Dave

[Eunosfield 0]

Mate this is sterling work!

I thought I was getting really involved when I stripped 3 seats to put one good non ripped one together,

but you've taken it to another level.

I'll watch your progress with interest, keep up the good work