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1" Upgrade for Bottom Instructions

1" Upgrade Cut and Install Instructions:

Quick Start:
1.  Use your existing pad material as a pattern.  Line up the back edges and mark the outline on the upgrade material .   Cut the upgrade material around the edges and the V.  

2.  Place the Crash Pad face down and open the Velcro bottom and put the upgrade material on the bottom of the stack, squeeze and stuff material up to the nose seams.

3.  Pull the Velcro loop tight around the edges of the 802SAM.   Flip the pad and pull the bottom around the back edge and Velcro the top in place. Flip the pad and tuck in the corners and wrap the flaps around the sides.  

4.  Read the detailed instructions Online (or below) for more information.


Detailed Instructions:

The 1" upgrade material is intended to be added to the 2" Crash Pad in the
 standard outer upholstery covering. The added thickness will fill the bottom and may expose a little of the Velcro loop around the bottom edges.

The 1" upgrade material is provided as one sheet of 1" thick 802SAM that is a 13 3/8" x 18" rectangle. Cutting the material should be based on the original layers that you have cut to fit your seat width.

Layout and cutting:
To layout the cut, place a 13 3/8" x 18 upgrade layer on a flat surface (somewhere
that a cutting knife won't damage). Place one of the original, fitted
layers from your Crash Pad on top of the upgrade material. Line up the back
edges and use a marker to draw the outline of the fitted layer onto the upgrade layer.

Use a sharp knife, bread knife, single edge razor blade or electric knife to cut the material.
Depending on the blade, a sawing
 action usually works best. Take your time.  You can
always trim more.   You can glue a piece back on with 3M 777 adhesive spray. 

Place the Crash Pad on a flat surface and open the Velcro seam at the back.  Flip the pad and 
open the flaps.   Lay back the fuzzy Velcro loop material and place the upgrade material on the
stack of 802SAM layers and slide and squeeze the material all the way up to the nose seams, 
centered on the V, with the back edges aligned. 

Make sure that the material is centered on the V.  Pull the Velcro loop tight around the edges of the 802SAM.  

Flip the Pad over and wrap the Velcro loop bottom material around the back edge and Velcro the top in place.

Flip the Pad over and, tuck in the corners and edges and wrap the side flaps up and around the 802SAM and 
Velcro in place. 

You should have about 1" or so of Velcro loop showing on top at the back. This is where the Lumbar or Back piece will connect.

Headroom:

Once you have put the Crash Pad in the seat, put on your helmet and get in
and sit down. Adjust your belts to your new seated height. Buckle up as
you normally would. You will preload the 802SAM material some as it
compresses and forms to you contours. After you have been belted in for
one minute, have someone measure from the top of the roll cage to the top
of your helmet. The typical recommended minimum is 3" but use the
recommended headroom by the car builder and other safety equipment manufacturers for equipment you are using.

Preload: When seated and belted in place, 802SAM will preload compress
about 40%. That means that a 2" pad will be 1 1/4" thick when a 170 lb
driver is belted in place. The preload compression will vary with driver
weight and other factors.

Don't compromise head room !!
If you now have insufficient headroom there are a few things you can do.
1. Lower the seat. As long as there is seat bottom clearance, remove
spacers or lower mounting bars to gain headroom.
2. If the seat can't be lowered, you can remove layers of the 802SAM
material in the Crash Pad. Remember that the thicker the Crash Pad the
better but if necessary you can remove a layer or two and still have some
benefit. The thickness and square inches of surface area of the 802SAM
are the keys to providing compressible space and shock absorbing resistance in an impact. It is better to adjust the seat height than remove material.
3. Order your next chassis with a tall cage for more headroom.