Wire frame construction
The XJ6 rear seat has a wire frame spring construction covered with burlap, foam, and a sewn cover.
The burlap covering, sewn or stapled around the wire frame, prevents the foam from compressing into the coil springs. Foam sections are tacked into position with stray adhesive.
Since we have eliminated the bulky retractable seat belt mechanisms (in both front and rear seats), the gap in the rear seat back must be filled in with an additional wire infrastructure.
Rounded corners were fastened to the existing frame with hog ties.
Fortunately, some non-US export Series 1 XJ6s did not install retractable seat belts, so these seat patterns have no gap. We therefore ordered no-gap rear seat covers.
Burlap and foam
After cleaning the wire frame, burlap was sewn to form a good platform for the foam sections.
Foam sections were then glued to the burlap platform. Note that the retractable seat belt gaps have now been closed!
The blue foam has an egg crate bottom. The medium density foam overlap at the top helps form a smooth rollover of the seat cover.
Initial fitment properly aligns all the foam sections with cover stitching. Then the cover is fastened to the back of the wire frame with hog ties and special clips.
When the rear back cusion cover is more or less clipped into position, a test fit is required to make final adjustments. These include the location of the top edge creases that should be hidden by the D post, padding at the top transition to the backlight shelf, and padding on the bottom edges that interface with the inside door frame.
The autopsy of the bottom cushion reveals a similar construction to the the back cushion.
The grey foam is egg crate and the yellow edge bottom is medium density. The restoration process is similar to that followed for the back cushion.
The armrest pull-down cushion operates on a metal hinge attached to the seat back.
A vertical backboard moves slightly up and down as the arm is raised or lowered, hiding the metal frame underneath.
Restoration includes painting the metal hinge to match the upholstery color (originally gun metal grey) and improving the backing flap attachment design with dual nylon straps. A new pull-over cover reuses the original foam pad, still in good condition.
Completed rear seat
Note: the blue wire at the upper left will power the demist feature on the rear backlight glass.