Since I have some injured fingers and I can’t type to fast, this is mainly gonna be a picture tutorial with captions. After much research about what works in seat shapes, what doesn’t, how to go about doing it, etc., this is the product. Thanks to Chrashing, John Childs, and Terry for doing the original poor man’s seat, giving me an idea of how to do the center cuttout, and giving me the idea of cutting out the saddle cover in the foam cutout area (of course I changed this a little).
Materials:
Drill
Duct tape
Serrated knife
pliers
marker
ratchet w/ sockets or socket wrench
ruler
flathead screwdriver
hacksaw (optional)
glue
scissors
staple gun (depending on drawstring cover or not)
drill bit
sandpaper
Remove seat from seatpost
Remove handle and bumper
Take off seat cover, do it very slowly or the foam will rip
Mark with a marker a line at the very edge of the curve on the top of the foam. You will be cutting this sliver off.
Once you have cut off the top sliver of foam, set it aside. Now mark two wedges on the front and back of the block of foam, being carful you won’t cut through the foam in the middle. You will have to decide for yourself, but I decided to make the bottom piece of foam that is left after cutting the two wedges very flat. You should make it as flat or curvy as you think will work best for you.
This is after cutting the back wedge. Now cut off the front wedge.
After cutting the front and back wedges, set the flat(ish) piece of foam aside. Discard (but keep) the wedges of foam. Now take out your drill bit, duct tape, and sand paper. Wrap the sandpaper around the end of the drill bit (covering the bit to the very end) and tape it at the base of the sand paper (make sure that it won’t fly off). (Thanks John Childes for the picture of the real tool in your coker seat mod album).
Get out the first sliver of foam that you cut. Now put the bit in the drill and holding the drill steady (and the foam!) drill a channel in the center of the foam spanning most of the way down the length of the foam. I made my channel ~17mm deep and ~20mm wide, but it’s hard to be exact with this sanding tool. I also made my channel gradually level out with the rest of the foam in depth.
Sorry for the small pictures.