How to Shape Motorcycle Seat Foam

Custom-shaped motorcycle seats feel more comfortable than stock seats.

Motorcycle seats from the factory have a reputation for being uncomfortable. Many times a rider needs to stop and get off the bike after only an hour or two of riding. Motorcycle seats do not need to feel this way. With practice and the right tools, you can shape your own motorcycle seat foam to make a seat that is very comfortable and looks just as good as a far more expensive custom seat.

Things You'll Need

• Motorcycle seat
• Markers
• High-density foam
• Electric knife
• Disk grinder
• Spray adhesive
• Eye protection
• Dust mask

Instructions

1. Sit on the seat with the cover removed. As you sit on the seat, determine where it would feel more comfortable if it had more foam, where it would be more comfortable with less foam, and where it just needs contouring. Mark these areas directly on the seat with a marker.

2. Remove foam. Where the seat needs large amounts of foam removed, use the electric knife to carve the foam. For smaller touch-ups and to smooth out rough areas left by the electric knife, use a disk grinder. A very fine grit pad works best to smooth the foam, while something with a bit more grit allows more foam removal.

3. Add foam. In the areas of the seat that need widening, or building up, use spray adhesive to join the new foam to the seat. Let the adhesive dry completely before you work on shaping the foam additions. Using the same electric knife and grinder combination, shape the added foam into the desired shape.

4. Test the seat. Put the seat back on the bike and sit on it in the same position you would sit when you ride. Wiggle around a little and mark any spots on the seat that need adjustment. Adding or removing very small amounts of foam can make a huge difference in the ultimate comfort level of the seat.

Tips & Warnings

• Work in small layers. The end result works best if the seat is shaped by shaving small layers in the final tweaking rather than taking off large amounts of foam all at once.

• You can have an upholstery shop recover your seat, or you can do it yourself. Make an inexpensive muslin cover first to get the fit right. After the muslin fits well use it as a pattern to cut your permanent seat fabric.

• Don't settle. If part of the seat feels a little wrong when you test it, don't figure it's good enough. Small problems will become big problems once you have sat on the seat for a long ride. Pressure points build up over time and cause discomfort, and discomfort while riding is a distraction that can prove dangerous.

• The fumes and dust from this project can irritate the eyes and throat. For safety, wear eye protection and a dust mask.

References

• Do It Yourself Motorcycle Seat: Adding, Removing, and Shaping Foam
• Obairlann: How to Reshape a Motorcycle Seat