Build a custom passenger

"Ghost" seat By Ted

I like the looks of my 9" wide rear fender so I removed the gaudy looking stock pillion seat.

(I plugged the three screw holes with plastic buttons which I painted to match the
fender so it could restored to stock in the future).

But there are times when someone wants to ride so I needed a quick remove/install passenger seat.

I used a piece of ½" thick high density foam rubber, the interlocking flooring that's used for childrens play areas. I cut it 6" wide X 10" long and radiused the corners. I used six 2½" diameter suctions cups from Michael's Craft store, the ones that are 2 for $1.79 with the metal hooks on them. They will be glued to the smooth side of the foam. Lay out the suction cups to leave ¼" from all the edges. Mark the center locations on the foam and push through an awl to allow expansion of the Gorilla Glue. I used a ½" masonry bit to drill the holes almost through the ½" foam. Wet the holes with water on a finger and apply Gorilla Glue to the suction cups tips and grooves. Insert with the cups tabs pointing outwards toward the edges. Weight it all down until the glue dries.

You will be gluing the textured sides to each other. When the glue dried I mounted the assembly to the fender and pressed all six suction cups down. I cut a second piece of foam larger than the first for the second layer and used contact cement to adhere them together. Let this dry overnight installed on the fender as this will make and retain the final custom contour of your seat.

This is the "formed" and dried assembly prior to sanding the edges and corners smooth and finished. The custom contour for your fender won't change now.

A view of the unfinished pad on the fender.

Lifting the little tabs on the suction cups in sequence will release the seat pad from the fender.

This is what the sanded pad should look like, wiped down with a damp rag and allowed to air dry. Keep it nice and clean for covering.

I used a fuzzy backed vinyl from Joann's Fabrics for the cover. The contact cement will cause it to wrinkle badly but don't let that scare you. When you're ready to press fit the cover on after the contact cement dries (about 15 minutes) it can be stretched to fit and the wrinkles pressed out. I first glued the vinyl to the top of the pad, then the edges and then the under edge. Using a hair drier to soften the vinyl as you're putting it on the foam helps keep the wrinkles in the corners to a minimum.

View from the side.

View from the rear.

View from the front.