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Bolens Model 1000 Seat Recover Project


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#16 29 Chev OFFLINE  

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Posted October 30, 2015 - 07:08 PM

Got the two pan pieces marked and cut out - had to cut an ear off of another piece to finish the corner for the rear piece as I did not have enough to do it in one chunk.  Got the ear welded on, welded in a couple of holes, ground the welds down and drilled six new ones in the bottom piece - two at the front for the mounting hinge - not sure what the other four were used for unless it was to hold it during the manufacture or future plans for another model??.  Then I found two lengths of 1/2" round stock and started to bend the one to shape - got it close but still needs a little work.  Maybe if things go good this weekend I can finish shaping the rods, see if I can roll the pan edges and get it welded together - time will tell. 

Attached Thumbnails

  • 1 Pan Pieces Cut Out.jpg
  • 2 Pan Pieces Other Side.jpg
  • 1 Ear Welded On Holes Filled And New Holes Added.jpg
  • 2 Ear Welded On Holes Filled And New Holes Added and round rod.jpg
  • 3 Starting To Bend Rod.jpg
  • 4 Starting To Bend Rod.jpg

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#17 blackjackjakexxix ONLINE  

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Posted October 30, 2015 - 07:27 PM

I would say your making good time on it,such talent
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#18 29 Chev OFFLINE  

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Posted October 31, 2015 - 05:07 PM

Got the rods bent to suit and the edges of the seat pan pieces rolled in the sheet metal brake.  Then I drilled three holes and slotted them with a cutoff blade in the die grinder so that I could verify the alignment and have a place to weld the bottom and back on to the rods.  Tacked things together and did a test fit with the remains of the plastic back - things looked good so I finished welding the tacked areas and welded two 5/16 nuts where the front hinge bolts go.

Attached Thumbnails

  • 1 Rods Bent.jpg
  • 2 Pan Edges Rolled.jpg
  • 3 Pan Edges Rolled.jpg
  • 4 Holes Drilled For Weld Slots.jpg
  • 5 Holes Slotted.jpg
  • 6 Peices Clamped.jpg
  • 7 Pieces Clamped.jpg
  • 8 Pieces Tacked And Test Fit To Remains Of Plastic Back.jpg
  • 9 Test Fit Of Plastic Back Side View.jpg
  • 10 Test Fit Of Plastic Back.jpg
  • 11 Front View.jpg

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#19 29 Chev OFFLINE  

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Posted October 31, 2015 - 05:10 PM

And then there were two seat pans.  Now comes the hard part of how I will do the back in hopes of keeping the seat looking as original as possible.

Attached Thumbnails

  • 1 Side By Side.jpg
  • 2 Side By Side.jpg
  • 3 Side By Side.jpg
  • 4 Side By SIde.jpg
  • 5 Side By Side.jpg

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#20 Bolens 1000 ONLINE  

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Posted October 31, 2015 - 05:11 PM

Great Work!!!


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#21 KennyP ONLINE  

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Posted October 31, 2015 - 05:37 PM

Coming along well here!


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#22 Chubien ONLINE  

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Posted October 31, 2015 - 06:13 PM

It's amazing, carbon copy of the original!
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#23 blackjackjakexxix ONLINE  

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Posted October 31, 2015 - 07:07 PM

Stew,your the man,very nice job !!!
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#24 29 Chev OFFLINE  

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Posted November 05, 2015 - 06:58 PM

Thanks for the kind words.

 

  After doing some thinking I have come up with a plan of attack -will have to see if it works out.  Since I now have a duplicate seat pan it will be the test model - that way if the modifications I make do not work out the two members original seats are still unmodified.  In my opinion the weak link of this seat design is the use of the plastic back to support everything at the outer edge - the bottom and back cushion extend about 3/4" out past the metal portion of the pan as you can see in the pictures.  Add to this that the cover was sewn all the way around the outside edge to join the plastic back and the front vinyl as well the white trim piece and you have a piece of plastic with holes from the sewing machine needle spaced about 3/16" apart creating a perforation line similar to perforations in a piece of paper resulting in the plastic breaking at this point from stress and vibration.  I could try and replicate a new back piece out of plastic or fibreglass but I think that would result in the same failure in a few years so my first step is to add an 1-1/4" piece of 22 gauge sheet metal along the outer edge of the seat pan by tack welding it to the edge of the existing pan.  This will make the seat much stronger at the outer edge where the trim goes.  The outer edge will be bent back to create an edge to form where the trim piece goes.  It is my hope to use white vinyl on the back and join it to the red cover at the edge resulting in a longer lasting seat covering that will look very close to the original as the modifications will be hidden.    

Attached Thumbnails

  • 1 Padding Larger Than Pan.jpg
  • 2 Padding Larger Than Pan.jpg
  • 3 Back Padding Larger Than Pan.jpg
  • 4 Welding Sheet Metal To Pan.jpg
  • 5 Welding Sheet Metal To Pan.jpg
  • 6 Welding Sheet Metal To Pan.jpg
  • 7 Welding Sheet Metal To Pan.jpg
  • 8 Welding Sheet Metal To Pan.jpg
  • 9 Welding Sheet Metal To Pan.jpg
  • 10 Welding Sheet Metal To Pan.jpg
  • 11 Welding Sheet Metal To Pan.jpg
  • 12 Welding Sheet Metal To Pan.jpg

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#25 29 Chev OFFLINE  

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Posted November 05, 2015 - 07:09 PM

Next I filled in the space at the bend to the start of the seat pan rolled edge between the back and bottom piece using sheet metal.  I rolled a piece to fit at the bend with the sheet metal brake and marked out the hand hole and cut it out with tin snips.  Then I used my flanger / punch to put holes in it around the edge of the hole for the staples to go through - not the neatest job but should still function and it will be hidden from view by the vinyl.  Then I did a test fit with the padding to figure out where the edge needed to be bent and shaped it.  Then I filled in the two side areas with small pieces of sheet metal at the bend, ground down and cleaned up the welds a bit and had a modified seat pan with an outer edge made out of steel. 

Attached Thumbnails

  • 1 Centre Piece Rolled.jpg
  • 2 Hole Rough Cut Out.jpg
  • 3 Hole Cut Out And Test Fit.jpg
  • 4 Side View.jpg
  • 5 Spotted In Place.jpg
  • 7 Spotted In Place.jpg
  • 8 Test Fit Of Padding.jpg
  • 9 Test Fit Of Padding.jpg
  • 10 Bending The Lip.jpg
  • 11 Filling In The Sides.jpg
  • 12 Filling In The Sides Close Up.jpg
  • 13 Test Fit Of Padding.jpg
  • 14 Test Fit ANd Edges Trimmed.jpg
  • 15 Welds Smoothed Down.jpg
  • 16 Welds Smoothed Down.jpg
  • 17 Side View.jpg

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#26 29 Chev OFFLINE  

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Posted November 05, 2015 - 07:10 PM

Then it got a quick splash of paint.

Attached Thumbnails

  • 1 Back Painted.jpg
  • 2 Back Painted.jpg
  • 3 Back Painted.jpg
  • 4 Front Painted.jpg
  • 5 Front Painted.jpg
  • 6 Front Painted.jpg
  • 7 Front Painted.jpg

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#27 blackjackjakexxix ONLINE  

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Posted November 05, 2015 - 10:29 PM

Looks pretty nice Stew
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#28 Austen ONLINE  

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Posted November 05, 2015 - 11:15 PM

That is a ton of work! It's going to be worth all the effort when you're done with it.


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#29 29 Chev OFFLINE  

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Posted November 07, 2015 - 07:19 PM

Made a covering for the two rods on the back by using some white 3/4" pvc pipe with a slit cut in it and a couple of modified pvc elbows - bent the pvc pipe with the help of a heat gun.  Could cover the back with the white vinyl and then put the pipe and ends over top.  I am going to wait until the white vinyl I have on order shows up and see if I can come up with another solution that will look more the same as the original back but this is one option that I came up with.

Attached Thumbnails

  • 1 Ready To Mark Tube.jpg
  • 2 Cutting Slot.jpg
  • 3 Slot Cut.jpg
  • 4 Split Tube Over Rod.jpg
  • 5 Tube Bent Using Heat Gun.jpg
  • 6 Wrinkles At Bend.jpg
  • 7 Wrinkles At Bend.jpg
  • 8 Wrinkles Reworked.jpg
  • 9 Wrinkles Reworked.jpg
  • 10 Back View Without Cap.jpg
  • 11 End Cap Added.jpg
  • 12 Cap Added.jpg
  • 1 Rods Covered.jpg
  • 2 Rods Covered.jpg
  • 3 View From Back.jpg
  • 4 View From BAck.jpg
  • 5 View From Side.jpg
  • 6 View From Side.jpg

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#30 Bolens 1000 ONLINE  

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Posted November 07, 2015 - 07:29 PM

Thats not bad at all!


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