MaksWerks Garage – Building a Custom Fiberglass Seat Pan for the Harley VROD

60 what’s up guys today I’m going to be showing you how to build a custom seat pan and so we’re building a custom seat for the v-rod project and this is going to be the first video and I’m gonna show you how to build a custom fiberglass seat pan and get it all finished then in a later video I’ll show you how to film in a holster installed and so forth because we’re working with fiberglass before I even get into kind of the procedure and the stuff we’re going to need the first thing I want to talk about is safety so pretty much everything that we’re going to be using in this project is dangerous the danger level varies from mild to extreme but none of these things are things that you want to expose your eyes your skin your lungs to certainly not for any extended period of time this is this is this is really really dangerous especially the the resin and the hardener this is stuff that you know has a real possibility of leading to blindness respiratory damage it’s irreversible you really don’t put your dick in any of the stuff that we’re going to be using they’re gonna want minimum 5 millimeter nitrile gloves you’re going to want quite a few of them you’re going to need them they protect your your hands you’re going to want to wear a long sleeve shirt obviously I’m just doing the intro video that’s why I’m not dressed appropriately but you really want to keep this stuff off in your skin as much as you the next important thing it protect is your eyes I highly recommend these these are made by 3m they’re about seven dollars on Amazon I’ll put a link in the description but they’re really nice glasses the face well and they have this rubber seal that can be removed on the inside I can show that here to the camera probably not focusing that well but it really seals up you know around your eyes quite well and that helps keep some of the fumes and the dust out and that’s going to be really important on top of that scription this I got this based on the recommendation of some other youtubers it is a full facial as you can see it protects all the way down to your chin and top of your head and this is great for grinding but it’s also going to be very important to make sure nothing’s Flyers up in my face it’s if it’s my head pretty well it folds up and down it’s got a lot of adjustability it’s not very heavy not obtrusive and you got lots of space for the next thing we need to talk about which is protecting your lungs 3m respirator 2097 paths are going to be fine for this you’re gonna see me wearing wool for a lot of the videos my new FST to overlay the audio or or simply record audio and then show you guys what I’m doing after the fact but this is extremely important these will do a good job of keeping fumes out of your lungs as well as fiberglass dust when we get there all things you really really want to avoid obviously a well-ventilated workspace we’re going to be doing some of this in the garage some of the knots at the garage but all that really pales comparison to good protection equipment if you don’t have this stuff what you see sitting on the table here is probably about $50 where the protective gear is some of the last stuff you’ll ever have to buy and so take the time spend the money do this or you’re going to be spending a lot more on hospital bills in very unpleasant circumstances okay the next step is things you’re going to need for this project that aren’t really materials in terms of like the project itself you’re going to need a roller I like these soft fluffy rollers this is helps get some of the excess resin off and gets all the air bubbles out you’re going to need a pretty accurate scale this is a little postal scale works quite well you want to go set it to gram it’s a little bit easier in metric and to get your ratios just right they’re not pictured here but you don’t want to give a pack of like Solo cups and wooden stirrers I have them and the part of the garage I forgot to get them out for this video but basically you just want something that you can mix epoxy in its like that and throw away when you’re done this is for like four five bucks you get a whole bunch of these little brushes from Harbor Freight like the whole box of 100 brushes were like four dollars or something and I really like that because I use them to apply the epoxy where it’s where you basically just slathering it on and turn you all the air bubbles out you know really care you just throw these in the garbage and never really worry about it another thing that might help something will prefer rather than measuring by weight you can also measure by volume in which case you’re going to need some of these disposable syringes they cost a few pennies each you can buy the bulk on eBay and in terms of making the fiberglass seat I think that’s pretty much everything you’re going to need

that’s not not a material now actual materials you’re going to need for the project this right here is about four and a half ounce fiberglass fiberglass cloth and as you can see it feels a lot like cloth it looks a lot like cloth and you can use fiberglass mat but since we want something that’s going to contour very nicely I use this heavier weight fiberglass cloth and it doesn’t have quite as much rigidity as the mat does but we’re going to we’re going to help it along its way and they’ll be rigid enough for what we need to do this is a better better material to use for this kind of project if you’re more comfortable using fiberglass mat or you have more of a flat rigid surface you can use that too it’s just kind of a personal preference in terms of cost this right here is I think like 30 square yards and set me back something like 25 dollars so fiberglass mat I’m sorry fiberglass cloth even this higher end higher weave count Claus it’s very inexpensive you use the same procedure with carbon fiber Kevlar if you want but they’re going to be dramatically more expensive something like 20 or 30 times more per square yard than just regular fiberglass cloth and unless you need it for structural use fire glasses or is a really good medium next thing is we’re going to be using this this is some sort of pro marine supplies knockoff ebay bought polyester resin and it comes with this this is organic peroxide Emmy KP this stuff is particularly poisonous and when you mix the two of these they’re very very dangerous they produce horrible fumes and vapors that’ll burn the inside of your lungs if you get it on your skin if you get it in your face and your eyes it’ll leave you blind it’s really really nasty nasty chemical you ship but when you mix this together it starts a chemical chain reaction gives you about thirty minutes worth of working time and this particular stuff it says from 3/4 percent to two percent we’re going to do one half percent and basically that means is that for every 100 grams of resin we’re going to put 1/2 grams of hardener in it and that’s just the ratio is designed to work at and you can buy different kinds I like polyester resin there are what’s called epoxy resins they behave a little differently and I’m not going to give them the differences for this video but a gallon of polyester resin will last you quite a while and I was just out so I decided to just go ahead and buy this this mix right here this is a good it has good reviews good quality mix I believe this was about forty five dollars for a gallon of this stuff the final thing is we’re going to use gel coat to seal everything and harden it when we’re done and that’s what this is this is black tooling gel coat with more MEAP as a hardener operates the same way equally dangerous stuff a smaller tub this was I think about twenty five dollars this is obviously a cord this is extremely flammable on top of everything else and again you’re going to remember what the ratio for this is I need to look it up but we’ll discuss that when we get to that part of the project but basically give this as the final coat on your seat once all the fiberglass cutting and sanding is done gives you a nice black finish going to very smooth like the underside of a boat for instance that’s what I use this stuff for and it helps give the seat a little bit of rigidity and a little bit of a better look when we’re done so these are the three main things you’re going to need the fiberglass cloth to lay the resin to cure and the gel coat to finish it off and when you have gotten past the stage that’ll be the end of this video and you’ll see that we have a really nice seat pan so the first step is basically to figure out the area where you’re working and then to seal everything else off so this is just standard tarp and blue paint air blue painters tape now you might ask yourself what is all this white stuff max well this is actually just standard care Anubha wax so I think it’s mothers or something the basically it’s going to act as a mold release so as you can see I taped up the whole area where we’re going to be building the seat and the way we want is we’re going to want the seat pan to go up onto the tank here down onto the tail here we’re actually going to go the full width of where you see all the white because it’s actually a lot easier to cut fiberglass down afterwards than it is to make it somehow bigger the other thing I did right here is I put the the hinge piece on so that it leaves a nice impression right here on the on the inside of the fiberglass and so that way we know exactly how to position this so we’re not accidentally shifted back to front left to right and so everywhere that you see wax is just to make it easier to take all this off after the fact you need to chop up your fiberglass and the way this works is you want three or four sheets that are going to be basically this full size so that

we can basically lay it down epoxy it and let it sit complete you know cover it everything out roll it out get all the air bubbles and stuff out and you want two or three sheets I’ll form your base and then you want a whole bunch of strips or squares or whatever and to reinforce it and you especially want to reinforce the outside edges where we’re going to be putting staples through to hold the leather in place so we’re basically cut out three or four of these squares I’m going to cut a bunch of strips and then we’re gonna have them ready to go because the epoxy only has a certain yeah it might be four basically the entire size that we wanted it’s a little bit narrow I would say because I really wanted to go over the edges so we’re going to make the other ones a little bit wider and we’ll use that as a finishing piece so there we go we have our big piece we have our medium pieces or strips and our small pieces and so that should be plenty of fiberglass at least for the first set we can always cut some more of this stuff if we need to and put it on there next I’m going to gear up a little bit set up the camera and get the epoxy mix and show you guys how all that works and and get started with that alright so here’s the setup this is me explaining ahead of time because once I get all my safety gear on it’s gonna be hard ha thanks we have two scales this one’s going to be for the polyester resin and this one is going to be for the MV KP this scale will do fractions of a gram and the scale only do one gram at the time and the gram of this scale will turn off after a while so we put your cup on it you may free turn on you put your cup on it it tells me the cup is 12 grams you will tear it out and to zero it out and so that’s how we’re going to do both of these and we’re going to start with we’ll see how much volume stuff this stuff is but hopefully maybe about 200 grams here and three grams here because that’s our ratio 1.5 grams to every hundred grams and so I got our our brush here ready to go and then we have a screwdriver here for mixing it up and other than that we’re going to basically put all of our gear on and then we’re going to mix it up and then we’re going to wear to have the first layer of fiberglass over there we’re actually going to lay down a layer then lay down the fiberglass then put down more resin and just keep going until I feel like we’ve got enough whenever you own this you man so – Atlanta so me sitting on G we have no you ain’t anything since I’ve been to a couple months whip into flame I play another richest man alive but I may be gay as long as you’re keeping one honey me Oh go for it she roll up roll up baby roll up roll up I I I like there you go that’s under 50 grams of

epoxy Wilson gives enough to do job hopefully this seat pan comes out stiff enough that we can use it alright well we’re back here and our fiberglass work is done and I didn’t film it but I actually did was I went back into the second layer of fiberglass with little strips going back and forth and up and down to kind of make sure we do get a really good a thick layer here don’t hit hard and so what you want to look for is you can see out here on the edge you see how if I do that it just cracks the the resin that means that your layer isn’t thick enough but when I go over here you see how the whole thing moves it doesn’t it doesn’t crack and splinter in through here so next step is we got to get this somehow off the bike and really you just got to kind of work it I got a little plastic spatula over there I’m going to use to get this off so once we get it up we can get this bracket mounted in here to help Center the seat so we can begin drawing one we’re going to that part is an ideal Toxie right out this piece of metal doesn’t lose any sort of cosmetic damage myself a little bit of epoxy to clean up here we can take that off with a little bit of alcohol actually we have our seat mold and obviously this is super huge we just got to kind of figure out how this is going to go in here then we’ll be able to draw on here and figure out how to cut it down good science here we already have our mold we know where this is going to go and so now what I’ve done is I mark the three holes and all we’re going to do is drill and put the stock bolts back through them that way we can get this mounted up to where it’s supposed to be and then I’m going to go with a sharpie around the edge so there that is Matt and then and one thing I want to point out is these bolt are flush like they were with the stock seat so we know that our fiberglass is about the right thickness spare to the original plastic shell I’m not going to be using these bolts finally because they’re pretty and I’m gonna get some real hardware but this should allow us to mount the seat up so curling all the material is on here I can actually get this slide image to work so we did a first little snafu in the sense that this can’t slide forward and back as it is right now because everything is so so flush and so big so we have it centered on these holes right here but it’s not bolted down but they will acting up and down on the hinge right now you just got to kind of figure out where it is exactly we want to cut and I think what I want to do is I want the seat to end basically right on these frame rails on the side the back we wanted to extend a little bit here on top and as you can see back here it’s it’s pretty loose because I have the tail off right now we wanted to extend a little bit back here to make God look there’s a quasi passenger see and want to go up onto the tank just a we don’t want to go up there a whole lot and so I’m actually going to do is I’m gonna grab the in a stock heat and see how it lines up with what we’re doing here and then kind of scale it on that amount of stock see looks like and that’s kind of what we want to mimic here you want kind of a narrower nose maybe four turns a little bit up onto the gas tank and we want a smooth line you can see that this right here is it’s flush so the frame rails run along the side of the seat and so there’s there’s no no side cover kind of on it towards the back we want just a small loop around here okay so they walk you through what I drew under here you can see there’s a sticker and that was always covered up by the stock seat so basically using this outside edge about where the stock seat was here we’re running I’m going to grind cut right here sort of kind of in the middle of this bar and then we can always grind it back as we need to it’s going to come up we’re going to have a bit of a squared off end back here then we’re going to come back around here follow the same line on the middle and curve around here and that’s going to be our seat but basically I’m gonna do is I’m gonna take me use this guy and we’re going to get all kitted up and we’re going to start to start cutting out pieces hopefully it looks good when we’re doing cutting plexi is a really really really not fun time so make sure you going safety here on 3a

Oh my brother never made it out she radome captain Oh I mean I still live like a selling gas in the Queen Emma’s really Michael I know you’re home well there we go it’s all trimmed down as you can see it will flip up there’s our hinge and we can actually slide this hinge on and off it’s really tight but it’ll work and so now we got to clean everything up get this rear panel reattached correctly so that will stay and next thing we got to do with this guy is we are going to apply a layer of gel coat to kind of seal all of this up I’m gonna go over maybe one more time just make sure all of our rounded edges are nice but this will make sure that you know all of this rough stuff gets covered up and smoothed over and so after we gel coat that’s going to be basically the end of this video but you can see our seat pan because we custom-made it it fits nicely here it’s nice and snug and the edge runs right along the bar up over here we have a nice little curve back here designed to look smooth with the curve that’s back here and so I think this will be really killer looking when we’re done unfortunately sanding fiberglass as you can see creates a hell of a mess so I gotta clean all this up first alright now that we have a trim down the other thing I do is I sanded down both sides of it rid of any burrs and we’re going to try to pull off much of this tape as we can basically get down to the raw fiberglass and next we’re going to have to gel coated and so gel coat is the stuff you find on the bottom of like a boat and I bought this stuff’s called black tooling gel coat and you use em ekp just like you do with tiga epoxy but the difference here is that whereas epoxy can be those are the polyester resin on epoxy can be measured out by weight or by volume this stuff has to be measured up eyeball you have to go to Home Depot or Lowe’s we can get one of these cups and what they let you do is it let you know that you put in 8 ounces and then you use the syringe to get a certain amount of cc’s of this stuff that matches up at the appropriate ratio and so I gotta look up what the ratio is for that but then we’re going to mix them up in this cup and we’re going to spread out here and this is going to be our finish so we want it to look pretty nice so if you’re using these cheap brushes like I am you want to make sure you really grab ahold of them and pull out any loose hairs again this stuff you’re going to want your respirator you’re going to watch your face shield it’s really not pleasant stuff with that said oh it’s getting mixed up and get started alright so I think that 12 ounces should be good to do the top and so according to this calculator from these folks the guys have made this 12 ounces is equivalent to about since it’s between 70 degrees Fahrenheit we need about 7 cc’s of this stuff so pulp fluid ounces right there we’re going to try to get as close as we can actually change our mind that’s a lot more than I thought it was so we’re going to go with a that’s 9 fluid ounces

that looks like it’s more actually to do both sides of this that is about 5.3 cc’s of death stuff mix is kind of like oil and so really want to make sure you crap out of your snare stapler I lose from maybe I didn’t spin the safe it is so crazy Oh well there you go obviously I’m just another idiot from the internet because that was clearly way way way too much for project like this you could use maybe like two ounces or something or four ounces I don’t know if I even use tap with what I put in there that’s alright everything was but just for this project so it’s not no great loss we had a nice thick layer on everything I’m just going to go ahead and let it dry I don’t know what the cure time on this stuff is but assume it’s like 24 hours like pretty much everything else either way we’re going to give it 24 hours to cure and I will show you guys what it looks like what’s up guys we’re back in the garage kind of wrap up our Harley Sipan video and so here you can see it’s mounted and you can see it looks really really pretty slick fits down nicely there’s a little bit of a catch right here where it’s hitting this part on this tail and I’m shaving that down a little bit but when it’s sitting all the way flush with weight on it you can see that the gap is really nice and it runs right along right along that plate and then over here runs right along the plate and so if I flip it up you can see that the hinge bolts up nicely it’s a little bit of a pain to slide in and out but it does work and I can lock it in and then we have this rip cord here to make sure the seat doesn’t fly off obviously when I do the foam is up I’m going to take this out and put it back but just for culmination of this video I thought I’d show you guys how it looks all put back together so kind of a little cost analysis the fiber cloth was about 25 dollars the resin was about 40 and the gel coat was probably another 25 or 30 so it’s about a hundred dollars of materials to get to this stage obviously I bought things in bulk you could probably do it cheaper you probably actually cut it down to about half that if you bought just enough materials to do this project so call it maybe 50 or $60 to get here assuming that you have none of these things at home in the next video I’m gonna show you guys how to turn that giant block of foam into a foam for your seat and then we’re going to wrap it in leather that’s for another video all-in-all I came out really well it really to me it looks very form-fitting I know it looks a little weird with just the gel coat on there but it looks a lot better than the garbage that was on there before and turning out to be a nice little project thanks guys you liked the video please subscribe check out my other custom motorcycle videos and make sure to follow me on instagram max works to see updates on projects like this long before the videos come out peace