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Hi Capn’s, Yesterday a little more work was done to Dauntless. I began slicing the Tempur-Pedic material for the cushions in the boat. I have waited years to finally bring this into being! At first I started cutting the Tempur material to be 1/8” thick but then quickly realized that it is not thick enough for that type of material because of the way it compresses. The thickness was changed it was cut 1/4” thick and it is now perfect. It has enough ‘meat’ to make a really comfortable seat. The Tempur-Pedic material is in the form of a block so what I did was put a ¼” tall wood strip against the side of the material and drew a line on the Tempur material using a thin sharpie marker. I went all around the material to form a cutting parameter. Afterwards I began carefully cutting the line with a razor. This was taking forever so I had to come up with another plan. So I went to the workshop and grabbed an Exacto cutting saw for the tool of choice. Once I began cutting it was sort of like cutting through bread with a bread knife. It was very effective and in minutes I would produce a cushion slice. I started with one of the seats just behind the helm. I put the seat foundation on the cushion, traced around it and cut it using scissors. Within minutes I had all four cushions cut out that make up the two seats. Next was the leather. I was a little intimidated by it initially because of the quality of the material, but that that went away within minutes. After carefully studying the leather and putting it over the cushion several times I came up with a game plan. The plan is to cut the leather about an inch longer than the seat foundation on all sides so that the leather will wrap around the seat and be trimmed further during the process. So I did just that. Once the piece of leather was cut it was wrapped around the cushion and seat foundation on two sides and then stretched the leather to see how much excess material was there. Afterwards I put down a thin layer of fabric glue on the top of the seat foundation and set the tempur material on top so that the cushion was adhered in place. Then I put the leather over the cushion and stretched it again to see how far it would go on the bottom of the chair. After a little trimming I used the fabric glue to glue the first sections of leather to the bottom of the chair. The fabric glue set in really fast so it only took a minute or two for the glue to hold the leather. Now there were the other two sides that needed to be stretched over the side and glued to the bottom of the seat foundation. To do this right it look a little more examining because it’s important not to have any creases as the seat forms. So after stretching, trimming and back and forth, I got the two ends trimmed so that they will pull over and appear neat. They were finally glued in place. The result was a really sweet seat cushion that I would love to sit on! (If I were a lot smaller) Also I estimate that it would cost hundreds to make each cushion in 1:1 scale. These seats will be fit for Royalty.. So far I made up one cushion and it will take two of these to make up one seat. Now that I did the hard part and came up with the assembly process it shouldn’t take as long to do the rest. I figured that I will be a pro by the time I’m done with these. There is another take away from this. I used basswood to make the seat foundation. I found this to be very useful because keeps the shape of the cushion together and helps by adding a good platform for gluing material to especially if you plan on using glue instead of stitching. I’m gearing up to make a lot of these cushions because each seatback across the back wall of Dauntless has the style that will require making several individual leather strips to make up that seating. It will also be the same for the seating in the aft lazarette and the bow cockpit. I plan on using more basswood platforms to get the shapes needed before wrapping them in the Tempur and leather material. I am estimating that there will be over 20 individual pieces of cushions assembled to make up the exterior of the boat. I didn’t photograph the process this time around but I will take a picture of the first cushion soon. As I make up the other ones I will have additional pics. -Rich.
< Message edited by Rich404 -- 1/30/2012 4:31 PM >
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