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I have some C7 Comp seats I will be using in one or both of my cars over time. I am just removing the side impact airbags today as they are vestigial and take up space. At some point in the future this space may have a roll bar passing through tightly, but that is undecided.
Removing the airbags leaves a large open cavity in the side of the seat. Both seat backs are equal opposites. My thought is to make a mold of the clean side of each one to then use with an appropriate smooth /shiny plastic (or paint one which isn't) and heat it to match the form and then cut it to fit over the cleaned up open areas.
My question is likely twofold then.
How best can I make an appropriate mold?
And what heavy gauge smooth plastics might be recommended for use?
I'd take an easier option. CAD template, transfer to sheet plastic. Wrap plastic in slim layer of foam then leather and glue on (alternatively you could cut the airbag bracket and do a couple of push clips into that).
If I had a scanner and knew how to use Fusion already, I totally would.
One friend suggested using bags with filler foam but I don't think that is my solution.
Clips could be done. One exists at the bottom forward point to be used. The rest I would shave off and possibly attach several clipping points from inside. But I would still need a fitted piece to mount.
Some angles. Anything sticking out I would want to remove.
Make molds, sculpted out of wood, then lay this plastic over it and use a heat gun to form it over the mold.
Remember to make the mold slightly smaller than the piece you want to make to allow for the thickness of the plastic.
This is the plastic sheet I used to form my CAI housing.
You could do it the old fashioned way and use dense foam that you attach temporarily to the seat, use various sharp tools to shape the foam to what you are looking for and then make a fiberglass mold. It is messy, but you can end up with a very nice piece eventually and then you can make the new cover from CF or fiberglass. The C7 seats need something similar done to the lower trim piece that houses the seat controls, since it seems that part requires cutting to fit in a C5.
Can you snap a pic of the backside of the airbag housing, Tusc? Im interested to see what the attaching tabs look like.
Maybe this is something a person with CAD skills can model out for 3D printing to add to your list? Design a "flat" cover with the airbag attachment points that could be painted gloss black?
A good idea to look at the frame, except one of the two tabs sticks out beyond the shell. The upper ear sticks out. The lower ear mounts to the seat frame directly.
@Davcruz I am going to err towards @JMG2 's approach of cutting the cheoa and easily replaced C5 trim as opposed to the insanely expensive seat base. I also have a set of C6 belts ready to go for the Z06.
My next headache will be removing either the entire giant electrical connector on the seat or removing only those wires which I need to run power. I'd like to remove the piece since it is a monstrosity.
Making Molds for Plastic
