Suzuki V-Strom (VStrom) Owners Club DL250, DL650, DL1000 & DL1050

V-Strom specific discussion => V-Strom specific discussion => Top Technical V-Strom Posts => Topic started by: MartinW on May 04, 2014, 19:57:03

Title: [0014] Fitting a Gel Pad into a seat (Option 2)
Post by: MartinW on May 04, 2014, 19:57:03
Summary: A method for fitting a Gel Pad into a seat. The original post was made by Willbo (http://www.v-strom.co.uk/smf/index.php?action=profile;u=2107) and can be found here (http://www.v-strom.co.uk/smf/index.php?topic=9818.0).

Just finished installing a gel pad kit to my 650 seat. all in all, including breaks, took about 4 and a bit hours. not rushing. The kit came from America, knoplace is the company name and they sell on ebay. All bits can be bought via UK too I must add. I only bought the American one as the gel pad is thin, but with a higher density to keep comfort. The DL650 seat is very thin on the foam front, so a thicker pad might not fit.

Tools used:

Started off by removing the leather, I marked up dead centre both to and bottom, to aid recovering. With the staples I took my time with to avoid rips. The staple remover was very handy, and the screwdriver to remove some stuborn ones. Also some rusty ones I must add.

I sat on the uncovered seat to find the "target area" and decided to pretty much cover the whole flat area. Once off, I marked up the position of the gel pad, I set the blade to correct depth for the pad and foam, then cut around the area, making sure I didn't go to far towards the sides and front of the seat. The foam is very thin here and I didn't want to go through. I then made 1" slices down the seat, to get the foam out.

Pulling gently, I removed each piece as a strip. This left an uneven but nice layer of seat foam, but something to work with. I used the sureform (very very handy ) £3 of fleabay, and smoothed the area best as possible. You need the flat area smooth, cos any bumps or holes are felt on the seat through the pad. I used the dremel very very carefully to smooth the corners. It did grip in once and took a chunk out. This I filled with spare foam.

I carefully measured and trimmed the gel pad to fit the hole, taking my time, as I have only one pad. Eventually it fitted in, but a bit big. Note to self, enure all cuts are fully straight next time, save cutting angles. I test fitted it, and felt the very slightly uneven base layer of foam. More smoothing later I got a good finish, then finished off triming the gel. Using the glue I fitted it in in place. Don't press too heavy with the smoother. Take your time and it will be a better result.

Now the memory foam. Because the seat is so thin, I decided to add a 5 cm length of memory foam so the crown jewels are at the front of the seat, futher on than the gel pad. I trimmed some more foam off the seat front, just thick enough to fit the foam in, without going too deep. Maybe 1mm protruding I think. I cut the foam carefully then glued it in place. I use the sureform to smooth the edges to level. The seat is probably 1mm taller now, but you can't really tell.

All smooth, I glued on the smoothing foam. This is just scrim foam 6mm thick. 1 side foam the other fabric. I stretched, glued, stretched, glued etc all over the seat. Starting in the middle and working front, sides back etc. Including right to the end of the seat. I have to cut here and there cos of the shape of the seat, there was a small patch of bare foam left, cos of the seat shape. this I cut a shape out of the exccess trim and filled in. No bumps, folds, creases or anything cos they will be seen or felt. Luckly I took my time and got it smooth. You can leave some eccess foam on, but not too much, remember, you don't want an untidy finish.

Now, recovering. You need 2 people for this, luckly my old man helped. Get the leather straight at the marks I made earlier. Attatched the front, then back, pulling tight. Then one side staple, then the other, pulling tight. Now I had the basic shape, I stapled the whole cover back on, changing sides if needed.

Hello presto. 1 gel seat all done. haven't tried it yet, its pouring. But it feels slightly firmer, yet more giving than before. All in all, cost about £110 including all tools, (except dremel) glue, and the kit. that includes £25 import duty.

Would I do it again? hell yes. I would still be nervous though about ruining a seat if I balls it up

For reading the essay, sorry its long, here's the pictures.

(https://farm3.staticflickr.com/2926/13920051188_5b3df9b75d.jpg)

(https://farm8.staticflickr.com/7296/14126732353_8e39fe84e0.jpg)

(https://farm8.staticflickr.com/7209/13920050928_0a6d78e902.jpg)

(https://farm8.staticflickr.com/7346/14106672125_f66a5f32a2.jpg)

(https://farm6.staticflickr.com/5334/14103574542_502a5ae131.jpg)

](https://farm8.staticflickr.com/7450/13920050738_c334a19dd1.jpg)

(https://farm3.staticflickr.com/2931/14106671585_441f32b6c0.jpg)

(https://farm6.staticflickr.com/5460/13920050588_e99afe4ed9.jpg)

(https://farm8.staticflickr.com/7402/14103574072_23dae75ea4.jpg)

Edit 1
There is a UK company selling gel pads on ebay. These pads they say not to put a layer of memory foam on top. So if I had bought one of those, and the scrim foam off fleabay, I could have done it a lot cheaper

Edit 2
I have now been for a really long ride, and you can really feel the difference (not car comfort, but much better). much more comfortable after 3 hours riding, but I did stop after 2 though, (cos of my dodgy knee). Before 1 hour and the pain/numb started, which didn't this time.

All in all, well happy.