Fiberglass Seat Pan Construction:

When working with fiberglass and a resin, you CAN build it faster than the directions tell you to. The important thing is to allow it to cool off, then cure....you can build it in one day and pull it the next. Having a hot mixture or adding too many layers at once (which increases heat build up) could cause it to crack or do damage underneath.

You can also add washers between layers to have strength at mounting points and drill them out later, leaving it nice and smooth. Use two layers of "1 oz Mat" (the fuzzy stuff) first, then one layer of a woven type fiberglass material (the shiny stuff), which may be the cloth type fiberglass provided in some of these kits. This adds strength and helps to keep your washer from pulling thru the fiberglass. Now add your washers, add a small piece of the Mat over each washer, then 2 more layers of the Mat. You'll be suprised with the outcome....a strong, yet thinner pan.

If possible, start your project in at least a 70 degree climate. Wax your bike and leave the wax on (you can buff the wax off when your finished) just in case you drip resin on the bike. If this happens, let the resin dry and it will pop off with the flick of your fingernail. *Do not try to rub it off while wet! You may regret it.

You probably will use 1/2 gal. of resin (with a little left over) per two layers. Have a gal. of "Acetone" for clean up of tools and hands. This stuff works great (same as fingernail polish remover) and it should last throughout your project. Don't get this stuff on your bike unless you plan on re-painting.

Caution! Your hardner, resin and acetone are extremely flammable. Also, do not allow anything rusty to come in contact with your hardner....BOOM! Do this project in a ventilated area.

Tools: Gloves, 2" natural bristle paint brush, 3" or similar paint roller , 2 big sheets of cardboard, 2 plastic buckets for mixing and cleanup, wooden stir stick, safety glasses and dust mask.

1. Lay plastic and foil to make the mold.

2. Spray with "Pam" (cooking sray oil) for good release.

3. Get your 1 oz Mat fiberglass ready. Work with approx. 6"X 12" pieces of fiberglass. You should overlap your fiberglass by 1/2 inch when you lay it in the mold.

4. Mix 40 cc's of hardner per 1/2 gal. of resin....= 2% ratio for proper cure. *never go under 1.5% or over 3%.....you would not get a proper cure.

5. Use paint roller to wet out fiberglass on one of your sheets of cardboard. Wet pieces with resin ONLY AS NEEDED. Do not wet all pieces at one time, the binder in the fiberglass will break down and you won't be able to pick them up without them falling apart.

6. Place one piece (in two layers) at a time into the mold, covering the entire surface. Shape gently as you go and leave some hanging off of the edge of the mold.

7. At your starting point, the fiberglass should conform easily to the mold. Using your paint brush (dipped in your resin), gently shape your fiberglass into the contours of the mold until you have worked over the entire surface. Patch as needed. Remove as much air as possible from under the fiberglass.

8. Clean up your tools and let the fiberglass set for about four hours or until dry and cool.

If you want to, you should now be able to gently remove the seat pan from your bike and finish it on your other piece of card board. You may also continue adding layers while it is still on your bike.

9. Repeat steps 1-8 with the woven or cloth fiberglass layer. Don't forget to add your washers and cover them with a small piece of Mat. Let this dry and cool.

10. Repeat steps 1-8 with the last two layers of Mat.

Let your pan set overnight in a warm area. Now your ready to cut to shape and drill mounting holes. Sand both sides, with 80 grit or similar sandpaper, until smooth. You can spraypaint the bottom of the pan for a finished look.

You are now ready to upholester.

Hope this helps and good luck.

*Do this at your own risk. I am only trying to help and can not be held responsible for any injury or outcome of the project.

Caution: avoid contact with skin and eyes. If you get anything in your eye, immediately flush with water for 15 minutes and drink beer until the pain has subsided. If pain persists, see your doctor.

If you have any questions or felt that I have left out a step, please shoot me an e-mail. I will be glad to help or edit instructions. If you don't follow the steps and your projects' outcome is unacceptable, find the nearest A-hole and punch them in the neck.