The front seat pans are a fiberglass tub that sits in the tubular steel cage, and gives the upholstered seat bottom somewhere to sit.
The issue with the standard seat pans is removal for annual inspections. To get the seat pan out, you must take off the seat back, and the floorboards. This is not a big deal, except that the alignment of the seat back sliding rails is critical for smooth operation.
Zach @ Fibertech Composites has a seat pan insert that drops in over top of the full tub. The bulk of the full tub is cut away giving access to wiring, control cables, autopilot servos, etc. This greatly decreases the time required to do many tasks. Very worthwhile upgrade.
Luckily for me, my seat pans were already rough fit. There were a few places that needed some work, but for the most part they were already fitting nicely in the cage well they are installed in.
Full seat pan with insert installed and initial cuts outlines to fit around seat tracks, flap handle, TD gear socket, etc.
First cut / fitting. Going to need lots of cleaning up.
I tried using a dremel oscillating tool (that I bought just for this). Not a fan for this application. I ended up cutting from the outside, and using a jig saw. I pre drilled all the corners.
Both seat pans cut and inserts fit as well. Seat backs clecoed in.
Done for now. Onto the next problem...
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