Step 11) Using 3-M spray adhesive, give 3 generous overlapping coats to the underside of the insert. Make sure to have good ventilation.
Step 12) Apply the insert to your base foam.
Step 13) Go to the store and pick up a $10 carving knife. No, do not use your wife's! She already hates you as it is from breaking wind and scratching yourself.
Step 14) Have at it! Cut a little at a time. This joker cuts foam like a hot knife through butter. Just take your time and trim where you want to trim. Occasionally place the seat on the bike to get a better look at what you are hacking off.
Step 15) Now comes the messy part. Once you are satisfied with the rough shaping, fine tune everything with a sanding block wrapped in 80 grit paper. Yep, you can sand foam. Take your time.
Step 16) Clean up your mess already! Use a shop vac to remove the mess you just made. Break out your staple gun and some 1/4" staples and go to it. I used 3/8" since that's what I had on hand, but they don't always fully seat at that length. 1/4" is better.
Start at the back of the seat and line up where the previous staples were through the cover and the pan. Put 3 or 4 staples across the rear. Put a couple staples in the front in the same place as well. Now start in the middle and put a couple on each side, stretching the cover taut. You will be surprised to find that the holes almost line up with the existing ones where staples were.
Now you will see how good your sanding was. Mine wasn't perfect and the seat cover is showing me where. So, take your time on the shaping portion of your project.
Step 17) Go test out your creation. If you don't like it, cry to your wife until she lets you order a Sargent. Remember, she is pretending to like you.
Here is my finished seat. I spent zero because I had everything on hand. I have more leg room to the pegs and my rear end is much happier.
Total time invested including this write-up? A little over 3 hours. Most of us watch more T.V. a day than that. So, turn off the idiot box and go make something!
I hope you enjoyed my silly write-up.