Plaid seats upholstery tutorial., Yes ! you can do it yourself. No special tool needed. Options

[johannes]

This tutorial will show you how to make yourself the cushion and backrest with the famous plaid inserts. No special tool needed.
For instructions on how to remove and desassemble the seats please read the excellent thread by Nick Mironov.
http://www.914world.com/bbs2/index.php?showtopic=71844

This is not a difficult job. It is long but I found it fun to do, and I learned a lot is the process.
Basic instructions on how to use the sewing machine was given by my wife and the instruction book that I always had next to me.

The plaid cloth was bought from Autoatlanta.
http://www.autoatlanta.com/porsche-parts/a...-and-Upholstery
I bought two yards as it was written somewere on this forum that on yard is for one seat.
I found out that I could cut 4 seats from theese two yards... but that was a very close (no error) fit.

The vinyl bolsters from the seats (back of the shell) were also changed and sourced from the same page on Autoatlanta 's website.

The headrest vinyl was saved from the existing cover. It is attached to the backrest. If your old headrests are not usable you can make new ones as I have already done
Follow the instructions on this thread:
http://www.914world.com/bbs2/index.php?showtopic=69300

What you will also need

A sewing machine. No professional machine needed. I used a 20 years old Husqvarna Optima 120. This one is simple and strong.
Vinyl for the side of the cushion
100 yards of thick yellow 100% polyester thread
50 yards of thick black 100% polyester thread
500g of Neoprene glue
Foam in different thickness...
Cardboard...

I cut the fabric using the pattern as reference. I used this picture found on this forum as reference. This is one of the few I found from an original seat.



The goal was to have three large stripes visible and centered.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236401.1.jpg)

[johannes]

While desassamblig take pictures for future reference.

Use the desassembled parts as reference and draw the shapes on a cardboard that will be your template.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236430.1.jpg)

[johannes]

First job is to cut the foam that will be used for quilting.
I bought a foam that has a thin layer of fabric glued on one side. I bought it from an upholstery shop.
I suggest you buy the same kind of foam. Otherwise you will need to ad a layer of fabric over the foam and it will be a nightmare to sew.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236459.1.jpg)

[johannes]

I wanted to have the quilting on the yellow part and used yellow thread. I chose not to follow the original quilting position as it falls randomly on black or yellow parts of the fabric.
I have one more quilting line than the original, but I found it easier to sew following the lines of the fabric.
With this template the first and the last quilting line is almost aligned with the original.


(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236498.1.jpg)

[johannes]

Use needles to first attach the foam with the plaid cloth

As the thread is very thick you will have to set the "thread tension" of the machine next to the max. See instruction book of your sewing machine.

Quilting next to a black line is easier. You can use the pattern as a guide.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236529.1.jpg)

[johannes]

First quilting is a bit off the black line, so it is aligned with the original.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236569.1.jpg)

[johannes]

At the end of each sewing, I make a knot to secure the thread. As the plaid cloth will be later wrapped around a thick layer of foam, you can stop the sewing a centimeter from the end of the foam.
On this picture you can se the white weaving that is part of the foam.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236607.1.jpg)

[johannes]

I attached the foam to the fabric at the bottom (here on the left of the picture) so It won't move during the sewing and I gave a bit of tension (see the foam bending).

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236642.1.jpg)

[johannes]

Once the quilting is over, you can sew the hew that will receive the wire at the bottom of the backrest.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236679.1.jpg)

[johannes]

Now sew the foam to the plaid at the top of the backrest. Later, the headrest will be sewed a few milimeters below so this sewing will not be visible.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236721.1.jpg)

[johannes]

Now sew the two side cardboards to the fabric. This has to be done by hand as your sewing machine will not be able to go thru the thick cardboard.
My cardboards were warped and in bad shape. I had to cut and drill new ones...

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236779.1.jpg)

[johannes]

Now sew the headrest a few milimeters lower than the previous sewing.
I glued a stripe of woven tape inside the headrest (grey metallic). As the headrest was previously sewed it is a good idea to strengthen this place.

Put the wire in the hem at the bottom of the backrest.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236807.1.jpg)

Wrap the backrest around the foam and glue the cardboards. Here the foam is yellow. It is a new foam I bought from the upholstery shop as the old foam was in bad shape.

Attach the top of the plaid cloth to the wire.

Your backrest is now ready to install.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339254872.1.jpg)

[johannes]

Now we start the cushion.

The cushion is more difficult to quilt and sew than the backrest.
Your quilting must stop on the edge of the foam.
When cutting the foam leave a lot of extra material. The foam and fabric will slip during the quilting process.
You will cut the foam later when assemled with the fabric because the two will have to match perfectly.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236862.1.jpg)

[johannes]

It is almost impossible to start a sewing precisely. But you can stop it with precision.
So, here is my tip: When quilting, start in the middle and stop at the edge of the fabric.
It should look this way.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236901.1.jpg)

[johannes]

Quilting the cushion. Start in the middle, stop at the edge of the fabric.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236937.1.jpg)

[johannes]

Once quilted you can cut the foam at the front of the cushion.
I used the green line as reference.
I made rectangular hole in the plaid for the metalic hook. I found out later the hole was not at the right place . I suggest you make this hole after you fit the cover on the cushion foam.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339236979.1.jpg)

[johannes]

Now it is time to fit the vinyl to the cushion. I cut the vinyl using the old cover as reference.
I reported the shape on a cardboad, then used the cardboard as a reference to cut the vinyl.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339237021.1.jpg)

[johannes]

First assemble with needles.
This is the tricky part because you will have three layers to sew togeter: Vinyl, plaid cloth and foam.

IMPORTANT !!!
You wont be able to sew the foam in the tight curve at the front of the cushion.
This is how I did:
I sewed the three layers from the back of the cushion to the beginning of the curve.
Then, from the curve I only sew the plaid to the vinyl. The foam is not attached from the curve.


(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339237068.1.jpg)

[johannes]

once the straight line is sewed, you can cut the foam.

(IMG:http://www.914world.com/bbs2/uploads_offsite/johannes.roussel.free.fr-5409-1339237104.1.jpg)

[johannes]

Wrap the foam so it won't be in the way when you will sew the tight curve...

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