Figured I’d give an update.
I bought a set of “roto-molded” bucket seat shells from Great Lakes skipper fir $89 ea. The fiberglass seat shells are so thin that when lifting yourself out of the seat, the thin edge of the arm rest cuts thru the foam. The plastic seat shells have a 1-1/2” wide edge. That alone is worth the investment.
Well, I liked the shape and height but didn’t think about the width when I ordered them. They were too wide!!
These shells are hard to find so I decided to take 2-1/2” out of the center and trim the “take out” down as a backer when I put it together. I could get a $19 plastic welder from Harbor freight but pop rivets worked great!!
Next I made up the rest of the interior from 1/2” & 1/4” birch plywood.
The contoured front seat bottoms was a challenge. I used two layers of 1/8” “utility plywood “ @ $11 sheet. The first layer got 1708 stitchmat on the bottom staying 2” away from the edge (for stapling) then covered in tin foil. Then it was put in place and a few self tapping screws held it to the contour.
When I un- screwed it the next day it rebounded slightly. I trowled on wood glue then the second layer and re-screwed to the contour. The next day I removed the screws and no rebound.
To be safe, I added a layer of 1708 on the top side. Now I have rigid full seat cushion bases.
With this solid base, I can cut more access storage openings under the leg area Under the front seating.
The new front side panels are attached to the back rest portion for a cleaner more modern look.
The rear side panels were made more modern and are roughly to shape. They are still oversized and I’m adjusting and trimming till they look correct. The ‘89 panels were too short and bulky in my mind. The ‘97 model I pictured above , to me, are too big as they go to the dash and the floor reducing side storage access. Trying to find a happy medium.
[ Post made via iPhone ] 
