BOM

For the bolster system there will be a total of four different configurations (these can be seen within the assembly model), they are as follows:

• Configuration 1 = 120 Degrees with Original Side Bolsters

• Configuration 2 = 120 Degrees with Raised Side Bolsters

• Configuration 3 = 110 Degrees with Original Side Bolsters

• Configuration 4 = 110 Degrees with Raised Side Bolsters

Below are two images which will show configuration 1 and 4 to show all the different parts

Instructions

1. If there is enough material available, and if the bolster system is feasible cut components 5-12 as per the provided drawings available on GrabCAD

   1. If there is not enough material or if the bolster system is not feasible cut components 5-8 as per the provided drawings

2. The nested instructions within this step are only applicable if the bolsters will be made, these will be used to orient the bolsters in the correct position when installing them

   1. From the bottom of component 9 or 10 measure 125mm up and draw a horizontal line

      1. Reference the CAD files for this if needed (will be named “Midline”)

   2. On the angled face of component 11 and 12, draw a horizontal line running through the middle (i.e. 0.75” from the edge)

      1. 

3. Place the Front Seatback Supports [#6] such that the side with a 130 degree interior angle is against the ground (see picture below)

   1. 

   2. Lay the Front Seatback [#5] on the upwards facing side of the Front Seatback Supports [#6]

4. Ensure that the Front Seatback Supports [#6] are approximately 7.5 - 7.75 inches from the edge of the Front Seatback [#5] (see picture below)

   1. 

5. Using adhering method of choice (e.g. wood glue) adhere both the Front Seatback [#5] and Front Seatback Supports [#6] in this way

6. Depending on which configuration is to be tested, the following instructions apply

   1. If Configuration 1-2 is to be tested utilize Side Bolster Support Block (120 Degrees) [#11]

   2. If Configuration 3-4 is to be tested utilize Side Bolster Support Block (110 Degrees) [#12]

   3. Place either component [#11] or [#12] away from the bottom corner of the Front Seatback [#5] in the orientation shown below

      1. 

      2. Adhere this block with a removable method (e.g. with an L bracket and wood screws)

7. Depending on which Configuration is to be tested, the following instructions apply

   1. If the Original Side Bolster is to be tested, utilize Side Bolster Original Simplified [#9]

   2. If the Raised Side Bolster is to be tested, utilize Raised Side Bolster Simplified [#10]

   3. Utilizing the lines drawn in step two, align the lines on Bolster (either component 9 or 10) and Support Block (either component 11 or 12) such that the lines are collinear (see picture below)

      1. 

8. Ensure the back edge of either component 9 or 10 is along the the Front Seatback [#5]

   1. 

9. At approximately, 30mm along the Midline, drill through the Bolster and Bolster Support Block with a wood screw, adhering both in place, but allowing for removal later on

   1. 

10. Place the Front Seatpan Supports [#8] such that the side with a 128 degree interior angle is against the ground (see picture below)

    1. 

    2. Lay the Front Seatpan [#7] on the upwards facing side of the Front Seatpan Supports [#8]

11. Ensure that the Front Seatpan Supports [#8] are approximately 7/8 inch away from the bottom corner of the Front Seatpan [#7] (see picture below)

    1. 

12. Using adhering method of choice (e.g. wood glue) adhere both the Front Seatpan [#7] and Front Seatpan Supports [#8] in this way

13. Ensure that the centre of the Front Seatback [#5] and the Front Seatpan [#7] are in line with each other

14. Now position them such that the Front Seatback [#5] and the Front Seatpan [#7] are 5.75 inches away from each other (see picture below)

    1. 

       If there is enough plywood, an extra large piece could form the bottom, upon which the Front Seatback Supports [#6] and Front Seatpan Supports [#8] can be screwed down onto with L brackets. ALTERNATIVELY heavy objects can be placed in front and behind of the Support pieces, preventing them from moving

BOM

Instructions

1. Cut components 1-4 as per the respective drawings (again these can be found in GrabCAD)

2. Place the Rear Seatback Supports [#2] such that the side with a 120 degree interior angle is against the ground (see picture below)

   1. 

   2. Lay the Rear Seatback [#1] on the upwards facing side of the Rear Seatback Supports [#2]

3. Ensure that the Rear Seatback Supports [#2] are approximately 3.25 inches from the edge of the Rear Seatback [#1] (see picture below)

   1. 

4. Using adhering method of choice (e.g. wood glue) adhere both the Rear Seatback [#1] and Rear Seatback Supports [#2] in this way

5. Place the Rear Seatpan Supports [#4] such that the side with a 135 degree interior angle is against the ground (see picture below)

   1. 

   2. Lay the Rear Seatpan [#3] on the upwards facing side of the Rear Seatpan Supports [#4]

6. Ensure that the Rear Seatpan Supports [#4] are approximately 7/8 inch away from the bottom corner of the Rear Seatpan [#3] (see picture below)

   1. 

7. Using adhering method of choice (e.g. wood glue) adhere both the Rear Seatpan [#3] and Rear Seatpan Supports [#4] in this way

8. Ensure that the centre of the Rear Seatback [#1] and the Rear Seatpan [#3] are in line with each other

9. Now position them such that the Rear Seatback [#1] and the Rear Seatpan [#3] are 4 and 3/16 of an inch away from each other (see picture below)

   1. 

   2. If there is enough plywood, an extra large piece could form the bottom, upon which the Rear Seatback Supports [#2] and Rear Seatpan Supports [#4] can be screwed down onto with L brackets. ALTERNATIVELY heavy objects can be placed in front and behind of the Support pieces, preventing them from moving