Howdy folks. Just wondering if anyone has any tips on how to repair a vacuum moulded foam seat. I’ve got a “SR royal vacuum light” seat with a big chunk out of the nose. I’m wondering if anyone has figured out a way to repair this type of damage.

It’s such a shame because otherwise the seat is in perfect condition.

I am not opposed to experimentation so if you’ve got ideas let me know. Thank you.

insulating or construction spray foam would do well. it's moldable and sandable. it would be on the nose, at least, so you wouldn't be sitting on it. then, just recover it

otherwise, try youtube. the atv and motorcycle guys probably have some good ideas, too

The construction spray foam is likely to be too rigid after setting. The missing chunk can likely be replaced with a piece of regular foam secured in place with a foam glue. This can be covered with gorilla tape or vinyl. The obvious issue is of what the acceptable esthetics is going to be. Myself I do not care as long as the saddle is comfortable. The longterm outcome is that the saddle lasts forever but it gets ultimately completely covered with the gorilla tape.

aesthetics is what i had in mind when suggesting the foam. it's not too rigid. compare to a brooks saddle nose...which is a chunk of metal underneath? anyway, i've been where he's at. (my dog ate my saddle..no kidding ) if aesthetics are a concern (they were to me), getting a good shape with regular foam was/is harder to do. if the nose area isn't too damaged...ie. not too big so as to be actually be riding on it....the foam will serve well to get a nice shape, at least

fyi, the spray stuff used for reattaching headliners in vehicles works really well for recover saddles. i'd have to look to see what brand i used, if interested

Thank you both for valid responses.

I am a bike flipper so aesthetics are number one for me. I know that should be the opposite, in which comfort should outweigh aesthetics, but when I send a bike out it has to look great.

I do have some marine grade Vinyl kicking around and have used the automotive headliner spray in the past as well so maybe I’ll just focus on rebuilding the nose with some compression foam.

if there is a high point the bottom of the saddle has five points of attachment to separate the rails from the padding so I’ll be able to get the cover tucked away nicely. Thanks again and I look forward to any further suggestions.

^ if you are a bike flipper, then economics are part of the picture. Recovering with marine grade vinyl that you already have might be the lowest cost for you. That's if you don't value your time at all. And if the vinyl is the appropriate color.

Otherwise, you might consider sourcing saddles from the far east to have in stock. Reasonable saddles can be had in the $10-12 range. You just need to think ahead.

Another source might be take-offs or saddles from the used bin at your local coop. Anyway, you do the math for yourself.

+1. You'd be doing yourself, the person buying the bike and the local bike shop/Co-Op all a favor by buying a saddle from the orphan saddle bin. Most are new saddles that have been traded off of new bikes that were sold.