Aluminium seat pan help

[JustcallmeMrT]

Hi gents, I'm looking to make a custom seat pan, and was thinking of doing it in aluminium.  What thickness would you use?  Is 3mm overkill - can I go thinner so it's easier to form?

[simonster]

I used 3mm ( actual measured thickness 2.75mm) to create my seat pan and it formed ok with a medium sized rubber mallet. It holds it shape perfectly but I personally wouldn't go any less than 2.5 mm as the costs and extra weight are negligible between those thicknesses. I've also formed a few other pieces in 3.5 mm and its strength seems to increase a lot for that extra mm and although its also workable you may need to add heat especially on tight corners or curves.


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[JustcallmeMrT]

Thanks for the info Simonster.  Any tips on which foam to use in the upholstery of it?

[simonster]

I formed the shape using heavy gauge upholstery foam cut into shape with an electric kitchen knife with a one inch layer of cushion foam topper. The heavy foam provides the firm shape and the cushion foam topper gives it the soft cushion feel through the seat.


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