DIY “Bottomsiders”

[Paul Miller]

I looked through past topics about replacing or repairing Bottomsider cockpit cushions but I didn’t  find any real answers so I decided to attempt to make my own. Turns out it’s not that hard. 

I did get a quote from C Cushions first but the shipping alone was prohibitive to western Canada.

I’m pretty happy with my results although if I did it again I might use Insolite foam instead of the 1 5/8” EVA foam that I used this time. The process is simple. Cut the foam and spray on a few coats of Plastidip. The result is a rino hide tough rubber film over a comfortable closed cell foam. The only “tricks” are getting the thinning and gun settings right and making sure to alternate sides when spraying to prevent cupping.

I trimmed mine with blue aerosol Plastidip and a stencil of some sandpipers in flight just for fun.

I can’t say for sure if Plastidip would be an appropriate re-coat for the (vinyl I think) failing coating on old Bottomsiders but my guess is that it would work just fine. It would be easy to test.

Paul M

NS30U #211, Sandpiper 

Cowichan Bay, B.C.

[Tim in STL]

Paul, those look wonderful.  Can you provide a bit more detail?  How did you get the radius along the edges?  How did you spray the Plastidip?  How did you build up the Helmsman cushion? etc., etc.?

Tim in STL

White O’morn NS26U

Harbor Point Yacht Club

West Alton, MO

[David Young]

Paul, I would also be very interested in any and all further information you can provide. We desperately need to replace our cockpit cushions. Thanks.

David Young

Bay Cat, 30U #402

Suttons Bay, MI

USA

[Paul Miller]

Thanks Tim,

I just started experimenting and I would recommend anyone else to so the same. Neither the foam nor the Plastidip is cheap so small scale experimentation is important.

I’ll answer any questions you have.

1) I routed the edges which, on EVA foam creates some rough bits but not too bad. 

2) I sprayed with a relatively inexpensive HVLP gun like this one:

https://www.lowes.ca/product/hvlp-paint-sprayers/wagner-paintready-station-744327?&cm_mmc=shopping_google-_-6444659901-_-75878086006-_-pla-823813262335&gclid=Cj0KCQiAiNnuBRD3ARIsAM8KmltqEaUWQyqjPiObdwGtEIGM-YJil8XOpLbg1pWe750mxHffHIQgv7IaAtRNEALw_wcB&gclsrc=aw.ds

3) The bump cushion is glued up layers of the seat foam using contact cement.

4) I thinned full strength Plastidip rather than using the “sprayable”. I used VM&P naptha as my temperatures were low but xylene would give more time in warm weather.

5) I cut the foam on my bandsaw.

That’s a start.

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Paul M
NS30U #211, Sandpiper

Cowichan Bay B.C.

[Paul Miller]

A bonus is that on cushion sea trials yesterday in 20kn of wind the rubbery surface on the helm cushion showed no inclination to slip when I was sitting on its corner while heeled over..... built in non skid!

[Ernie Abugov N22 - #56 "Moustaches" Toronto]

No guff, Paul -

These are some of the neatest cockpit cushions I have ever seen, anyplace. The idea of spraying on a "cover" instead of upholstering the foam is absolutely brilliant. The workmanship is superb.

You should (seriously) bolster your retirement income by doing this commercially - you've got the skill set. And, you can balance out the "Western alienation" with the fact that you can go sailing NOW, lucky devil !!

Ernie A. in Toronto (where you can't really go sailing).

On Thursday, November 21, 2019 at 3:37:25 PM UTC-5, Paul Miller wrote:

A bonus is that on cushion sea trials yesterday in 20kn of wind the rubbery surface on the helm cushion showed no inclination to slip when I was sitting on its corner while heeled over..... built in non skid!

On Thu, Nov 21, 2019 at 12:30 PM Paul Miller <sandpip...@gmail.com> wrote:

Thanks Tim,

I just started experimenting and I would recommend anyone else to so the same. Neither the foam nor the Plastidip is cheap so small scale experimentation is important.

I’ll answer any questions you have.

1) I routed the edges which, on EVA foam creates some rough bits but not too bad. 

2) I sprayed with a relatively inexpensive HVLP gun like this one:

https://www.lowes.ca/product/hvlp-paint-sprayers/wagner-paintready-station-744327?&cm_mmc=shopping_google-_-6444659901-_-75878086006-_-pla-823813262335&gclid=Cj0KCQiAiNnuBRD3ARIsAM8KmltqEaUWQyqjPiObdwGtEIGM-YJil8XOpLbg1pWe750mxHffHIQgv7IaAtRNEALw_wcB&gclsrc=aw.ds

3) The bump cushion is glued up layers of the seat foam using contact cement.

4) I thinned full strength Plastidip rather than using the “sprayable”. I used VM&P naptha as my temperatures were low but xylene would give more time in warm weather.

5) I cut the foam on my bandsaw.

That’s a start.

On Thu, Nov 21, 2019 at 12:10 PM Tim in STL <whiteo...@gmail.com> wrote:

Paul, those look wonderful.  Can you provide a bit more detail?  How did you get the radius along the edges?  How did you spray the Plastidip?  How did you build up the Helmsman cushion? etc., etc.?

Tim in STL

White O’morn NS26U

Harbor Point Yacht Club

West Alton, MO

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Paul M
NS30U #211, Sandpiper
Cowichan Bay B.C.

[Paul Miller]

Thanks Ernie,

I’m at the age where time is more valuable than money. I will happily help anyone who wants to make their own but I’ve had enough businesses in my time and I’m not interested in getting into all that again. 

I think it is well within the abilities of most (handy) people and the great thing is that just about any mistake you make once the cushions are cut can be covered by another coat, which makes the cushions tougher. Can’t lose.

Now, all that said, I did make a set for a friend with a lovely little schooner.

[Ernie Abugov N22 - #56 "Moustaches" Toronto]

I'm at the same age, Paul. I'm retired now and don't know how I found the time to go to work.

Ernie A. in Toronto

[Anita Bleick]

Paul, if you are coming to Winter Rendezvous in Victoria this February, would you please bring down a cushion to show me “in real life”? I want to make those but have no familiarity with Plastidip. I’d like to see up close what I’ll be trying to replicate.  :-)

Anita Bleick

NS30C #65, Ilse B

Bowen Island, BC

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[Paul Miller]

Hi Anita,

I’m not sure if I’ll be there or not but I’m only an hour away so we can work something out. You can email me if you like <sandpip...@gmail.com>

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