Loading... Please wait...

Crash Pad Assembly, Care and Use

INSTRUCTIONS  for cutting, covering and installing, tips and tricks,  care and use of
The Crash Pad
You would think using a seat pad would be simple, but we're engineers and we sweat the details. 

802SAM and Temperature:

Let it warm up !!

When 802SAM is cold (below 50 degrees F) it can be broken like a cracker if you try to bend it quickly.   Let it warm up and move it slowly before it is at room temperature (including coming out of the shipping box from a cold delivery truck). 
You can glue 802SAM with 3M 777 adhesive.   It is not necessary to glue layers together.

802SAM becomes stiffer in colder temperatures.   This characteristic does not change the high speed impact absorbsion capabilities or performance in a significant way.  Body heat helps mitigate the changes. 


802SAM is an open cell material.  It will absorb water, mud and dirt.  
802SAM will lose its shock absorbing capabilities if the open cells are filled with material other than air.  
Do not use raw 802SAM without some covering (at least a cloth or plastic bag) to keep dirt and water out.
802SAM can be washed out like a sponge but due to the small size of the open cells it may take some time if it has been saturated with mud or dirt.
If it absorbs water, just squeeze it out very slowly against a flat surface.   The best way is with a rolling pin, pipe or similar.   
802SAM works by expelling air from its cells so total sealing is not recommended, and some venting space is required. 


Fitting to your seat

(see detailed instructions further down)

1.     Measure seat width from side to side at the back and front of the bottom.

2.    Cut an equal amount from each side of the 802SAM center line to fit to seat width and taper.

3.    Place upholstery face up and fold back the top covering.

4.    Wiggle 802SAM material into the V and up against the front seam.

5.    Center the 802SAM and pull the Velcro loop material tight and around the back edge.

6.    Pull  the top cover tight and Velcro the top at the back edge from the center out.

7.  Flip the pad, tuck in the corners and pull the side flaps around the edges and Velcro in place.

8.  Follow similar procedure to assemble Lumbar or Back Pad.  Center the 802SAM to start.

9.  Velcro the bottom edge of the Lumbar or Back Pad to the back edge of the Bottom.  
         Use the two Velcro hook strips to tie the back and bottom together.

10.   Remove any foam or rubber from the seat where the Crash Pad rests

11.    Press the Crash Pad into the bare seat as far back as possible.  

12.    Sit in the seat for a few minutes to conform the Crash Pad to the seat bottom.


See detailed Online instructions below for more information, tips and help.



802SAM Shock Absorbing Material
can be easily cut with a single edge razor 
blade, sharp extension knife, bread knife or electric knife. Draw a line with a marker and follow to cut for a clean edge.

Crash Pad Thickness: 
The thicker the better. Take a measurement for
rollcage headroom as instructed at the end of installation.

802SAM                                                 Preload 
Raw thickness:                          Thickness with driver seated and belted (typical)
3" best                                         1.75"  +/-
2" good                                        1.25" +/-
1" better than nothing                  0.6"  +/-
Nothing is asking for trouble.       0.0"     

802SAM is 18" wide when shipped. It can easily be cut for seats that are narrower. 

Measure from vertical side to side width to determine seat bottom width.
Seats are typically wider at the front edge than the rear so measure both and cut to fit that taper.

Subtract the measured width from 18" and divide by two to find how much to cut off each side of the V.
(Example: A 15" measurement would require 1 1/2" to be cut from each side of the 802SAM shock absorbing material to keep the V centered).
Some seats may be tapered front to back and you can tailor fit the material to the shape of the seat.

Generally you should not need to shorten the front to back length of the material. However if you have a short seat bottom, you may let the front of the Crash Pad hang over the front of the seat or you can shorten it by cutting 802SAM material off the front of the V (not the back edge).
The empty outer covering can be tucked under if desired for best installed appearance.

Outer covering: Once you have sized the 802SAM shock absorbing material
to the seat bottom you can insert it into the outer cover.
Put the cover on a flat surface with the fuzzy side down. 
Fold back the top cover material and work the 802SAM all the way up into the V at the front and against the front seam.

The Velcro is military grade and easily sticks together. Make sure everything is unhooked when you start.
Once the 802SAM is in place and centered, pull the Velcro loop material tight and around the back edge.



 Pull the top cover tight and Velcro in place.
Flip the Pad and fold the Velcro loop sides over and around the edges of the 802SAM.

Fold and tuck the corners of the top material like gift wrapping or a bed sheet corner, at the corners of the 802 SAM.


Pull the side flaps up and around the edges and Velcro in place. 
The corners will have a finished look with edges rolled under and flaps tucked in. 

Check to see that everything is still centered.cp-assemble5-sm.jpg

The Crash Pad bottom should now be fully wrapped with an inch 
or so of loop material exposed along the back edge at the top. This is
where the seat back or lumbar pad will connect.

Lumbar and Back Pad: 
The lumbar area is important to allow the pelvis to roll back in a vertical
down impact. It also adds comfort to the seat. The first 8" above the
bottom pad should always be a minimum of 1" thick. In a full shoulder
height back pad, the thickness can be reduced above the lower 8 inches for comfort or your feel or position in the seat.

Cut the 802 SAM to fit the seat width or try it wider if desired. You can
try it at full width and cut it down as needed for the best feel.
Now that you have done the tricky bottom, you can follow the same procedure
to load the 802SAM into the covering. Make sure that the Velcro hook material strip on the smooth side of the outer covering bottom edge is free

and not stuck to the Velcro back. This strip will later be used to connect the back to the bottom.

Center the 802SAM material on the inside if the smooth outer covering and fold the loop material over, tuck in the
sides and pull the smooth covering flaps over and Velcro in place. Flip
it over, tuck in the corner material and fold the smooth covering flap over the top edge and Velcro in place

Center the lumbar pad over the bottom pad so that the strip of Velcro hook at the bottom edge of the lumbar (or back) pad sets on the edge of exposed Velcro loop at the rear of the bottom pad and connect both pieces Two Velcro hook material strips are included to help hold the back to the bottom. These strips can be put on the back edge of the bottom pad, about 4" to 6" apart connecting the bottom and the back together on the back side of the lumbar (or back) pad.

Remove any foam, cushioning or rubber from the seat.  That material does not help in an impact and just takes up Crash Pad space.   With the pad assembled, just put it in the bottom of the bare seat.


There is seldom a need to Velcro the Crash Pad bottom to the seat but you can if you want to by putting a strip of adhesive backed Velcro hook on the seat bottom and or back (not supplied).    You may want to put a strip or two of Velcro hook on the seat back to hold up the shoulder height back pad.


The Crash Pad installation should be made so it is easy to remove when you wash the car.


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.

Crash Pad thickness is what it is all about.

802SAM                                                 Preload 
thickness:                          Thickness with driver seated and belted (typical)

3" best                                         1.75" +/-
2" good                                        1.25" +/-
1" better than nothing                  0.6"   +/- 
Nothing is asking for trouble.       0.0"     


 - Tips and Tricks -


Bottom taper:

Some seats are formed with diagonals from the vertical sides and back to the bottom.
You can custom fit your crash pad to the seat pan by cutting the 802SAM at a similar angle.
This can be done by fitting each layer of 802SAM in the seat bottom, one at a time.

When you wrap the stack in the outer covering and it will fit the seat bottom like a plug. 


Lumbar top edge:

You can cut the to edge of the 802 SAM at an angle to create a more comfortable transition
from the Pad to the seat back.
A good starting point is to mark a line 2" down from the top edge of the 802SAM.
Then mark a line on top edge about 3/8" from the back corner.

Put the material on the edge of a bench and make the diagonal cut.

Assemble the Lumbar outer covering with the taper facing forward toward smooth outer covering.lumbar-cut2.jpg


Remove the wrinkles:

Wrinkles are caused by curves and corners.   The outer covering goes slack when the Pad is curved or bent.

Bottom taper above will remove wrinkles from the bottom pad or you can do as below.

To minimize wrinkles, assemble the Pad pieces on a curve or a bend.   One easy way is to fold the piece
over a curved surface (like a tire or a wheel) or over the edge of the bench when you pull the side flaps tight and Velcro in place.

Then put the top (face) Velcro in place after. This will pull the front of the outer covering tight across the curved 802SAM 
inside.  Put the Crash Pad in place and adjust the Velcro to remove remaining wrinkles.   It takes some tinkering
but when you get it right it will stay that way.