new seat foam fj60

[WoodnotRust]

Option #4:. Cut the foam from underneath to keep the form. Maybe some drilled holes to add comfort to the cheek and tailbone area as well.

@MoaByte was exactly correct. I returned to the shop this morning and Jake (House of Covers, Albuquerque) proposed we just skip the hole-drilling only option because it was just obvious that the seat foam was too high. They cut about 1-2" of foam from the bottom and drilled multiple 3/4" diameter, 1-1/2" deep holes in the center foam and narrower and deeper holes along the sides. Holes are drilled from the bottom side and a lip of original foam was kept around the perimeter base.

The first try where every hole had the foam pulled out felt just a bit too soft for my 205lbs, but the height was perfect. I asked them to keep the foam in about half of the holes on the second seat and this was still firm, but the height was just about right. Now the "softer" seat (and it is barely softer...still pretty firm actually) is in the passenger side and I have a "firmer" seat for the drivers side. Both aren't as rock hard as the original SOR and are covered with 1/2" softer foam on the top.

I'm really happy with the result. Here are pictures: The first is the original SOR seat no mods, next pics of cuts from bottom and hole density for both. Last pic is the final seat after mod. My head height is 1-1/4" lower post-mod and it is a lot easier to climb into the truck. Success!

 

[John Staton]

thanks for this write up. I am always looking for low cost projects on my truck, which is pretty much the way I like it, but at 6'1" if I sit up straight I do touch the headliner. I am going to try this on my sor cushions.

 

[Thuleman]

So it’s now 2025. Has anyone sourced a better replacement seat bottom for the fj60s? Such a common problem and there has to be a better solution than SOR or re-using salvaged seat foam. Any new vendors?

 

[thewrongwizard]

So it’s now 2026. Has anyone sourced a better replacement seat bottom for the fj60s? Such a common problem and there has to be a better solution than SOR or re-using salvaged seat foam. Any new vendors?

 

[Roonie]

I used the SOR foam bottom replacement in both of my seats and did the hole drilling and had to cut off about an inch off the bottom of the new seat foam. I added soft 1' foam on top as well. I find the seat really comfortable now and no problem for long car rides. I added foam on the back as well for more lumbar. New seat covers from cruiser corps that look like OEM. I am happy with the final product looks like OEM but way more comfortable. Finished this project about 2 months ago.

 

[Michael Hanson]

So with all those drilled hole could we not run ac to the seat bottoms

 

[Roonie]

So with all those drilled hole could we not run ac to the seat bottoms

Sure. I am old school though and the only thing I would add is heat but I didn't even add that. I think it would be easy to add maybe?