The following photos show the process of making plugs and molds for the seat pan and seat back. This process is much the same as the ASH 26 I did on the ISSA Tech Tips page only here I decided to use polyester resin insted of epoxy.
Can't have enough good referance photos. Shots of a 28 and a new 29.
Here I took the stock seat pan, cut the sides off and started forming the new pan with 3lb foam.
Here is the new roughed in pan.
New pan checking for a fit.
Checking to see if Axel likes the fit.
Shaping the seat back, again 3 Lb foam.
Here is the newly shaped seat back ready to make a mold from. The seat is designed to hold the pilot in place with one screw for easy removal.
Here are the final molds, I will lay up a light weight parts in polyester.
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