TThis now leaves the steel part of the rebuild process
On the back, if the lumbar support feels loose, it is probably because the steel crossmember is cracked. Repair by rewelding it.
Now onto the seat base
Take a close look at the grid with the springs. Check for any broken spokes. This seat had two
Check where the springs are attached as well, to ensure they arent very worn
This set wasnt bad, but when I redid the seats when I got my truck, they were worn in twice as far.
If you have a welder, this is a good time to reinforce that area.
If you bend up the tabs at the front of the grid, it will free it from the seatbase
Now for the fun part. I thought it was odd that the grid was not supported the whole way across the front , so I undid all the spokes and got a longer front rod, so that it would reach to both sides as well as the tabs at the front. I then made a hole in the sides for the rod to sit in, and replaced the grid into the tabs
The spokes are just bent around and attached to themselves. I bent them off with a pair of pliers, and rebent then when going around the new rod.
Re-attach the springs at the back with a screwdriver. It makes life a lot easier. Hook the spring on the shaft of the screwdriver, and place the other end over the grid, pull on the screwdriver, and the spring will slide down the shaft onto the grid
I added the spring in the middle, as well, as not indicated in this picture, if you want a firmer ride, fill up all the holes with springs. When I redid my seats, I did not do this, and I wish I had.
Thats about all you can do with the seat pan. Onto the Foam
I did a post a while back about using aerostar seat foams. I still had a piece of foam from those seats, as well, the passenger foam was still good from the 94 seats. I chose to use the aerostar foam, as I knew it had even less miles on it than the 94 seats did.
I glued small pieces of strip foam that I cut from the old foam into the grooves of the aerostar foam. This was just to make sure that it was one solid piece of foam. You can get away without this, but I wanted to do just to make sure everything stayed in place. I used 3M Super 77 spray adhesive.
I needed to cut a few notches in the foam, to accommodate the plastic screw covers and the hoses for the airbag
Here is the hog ring bar in the aerostar foam
and the hog ring bar in the F-150 foam
Nothing too technical there, just the place where the seat cover attaches to the base. The difference between the two foams is the distance from the top of the foam down to the hog ring bar
SIDEBAR: If you are using a passenger side cover to redo your drivers side, make all your cuts before reinstalling the cover. I just held the two together side by side, and drew through the holes to make the marks for the new holes. Also since there would now also be holes where there were no holes before, I sewed a piece of cloth in behind the holes that were no longer required. I figured this would help keep the seats looking better longer, without stretching the holes out.
There is over an inch of difference. This makes reattaching the foam difficult with hog rings. I used cable ties. Its probably not the best idea, but it was all I had
The length you make the cable ties determines how far the seam of the seat goes into the foam.
If you are using an Aerostar foam, it will not have the velcro strips on it for holding the fabric down. I have not noticed a real difference not having the velcro on there. If you were concerned about it, I guess you could Super 77 both sides to ensure it sticks.
Its time to reassemble.
Place the foam with cover on the seatpan
Lean on the seat and hook the plastic retaining clips back onto the seatpan. Make sure that the foam that skirts the seatpan is in place, and not bunched up.
Make note of where the hole is for the Seatback airbag hose. I just about forgot, so I just grabbed my keys and stuck them in the hole so I wouldn't lose it.
Once all the plastic retainers are on, you are finished with the seat base
Now the reassembly of the Seat Back.
Stretch the foam and cover over the seat back frame again. The plastic pieces on the bottom are easy to reassemble. Stretch the fabric until you get a fold in the straight plastic piece, and fold it into the c shaped part.
Once you have that done up, you can reinstall the seat back onto the seat base. I apologize that I have no pictures of the re-assembly. It is basically the reverse order of how it came apart.
Hopefully this helps