There's a reason the phrase "seat-of-the-pants" exists. Your seat is your most intimate, direct connection to your rig. A comfy seat means a more comfortable ride means a better experience means happier memories.
Since the initial installation into our '04 4Runner (see "Superior Seating," May 2010), we've spent a lot of seat time in the MasterCraft Safety Baja RS recliners up front. They were holding up well, but we'd come to regret not having ordered the optional adjustable lumbar supports in the first place. Why had we skipped the adjustable lumbar supports? The OEM Toyota driver's seat featured an adjustable lumbar support that was way too firm, even at its softest setting. We feared the same might happen with the Mastercraft supports. It turned out that long days combined with rough trails left us quite literally feeling the need for additional lumbar support.
Here's our mandatory "before"...
Here's our mandatory "before" shot. Despite lots of miles, dusty trails, and plenty of snacks consumed behind the wheel, the driver’s seat was still in remarkably good shape.
In addition to wishing for the adjustable lumbar support, we wished we'd paid closer attention to our chosen color schemes during the initial order. Both the Baja RS seats up front and the Sportsman seats in the second row looked great, but the colors didn't match. This was our mistake; MasterCraft built the seat covers exactly the way we'd requested.
This is a situation where MasterCraft really shines. Thanks to in-house manufacturing, MasterCraft is ready to provide follow-up service for the seats it sells. Are your MasterCraft seats looking war-torn and weary? Does the internal foam have more miles on it than you care to admit? Do you want to add an optional feature the way we did? When you invest in a MasterCraft seat, you're buying long-term comfort and style.
MasterCraft's marketing manager,...
MasterCraft's marketing manager, Kelli Willmore, showed us additional aspects of seat building. Each seat frame is built in a precision fixture that is used for tack welding. After the pre-bent, laser pre-notched tubing is assembled to specifications, it is removed from the fixture and hand-welded at a dedicated welding station.
We paid a visit to MasterCraft Safety's headquarters in Santee, California, and followed along while the longed-for adjustable lumbar supports were added to our Baja RS seats. After the lumbar supports were in place, a new set of seat covers provided a fresh look and corrected our previous mismatch mishap.
Our seat-of-the-pants impression? We needn't have worried in the first place. Adjusted to full soft, the lumbar supports are barely firmer than the seats were without them. At full opposite lock the support is abundant and unmistakable. Our sweet spot was in between these two settings. With custom-tailored lumbar support at the turn of a knob, there are miles of smiles ahead.
After they’re welded, seat...
After they’re welded, seat frames get a rugged powdercoat finish. Next, the nylon-coated textile suspension liner is wrapped around the frame and secured in place using nylon parachute cord that’s passed through double-lapped, grommeted attachment points.
Foam of varying thicknesses...
Foam of varying thicknesses and shapes is glued onto the suspension liner, but the real point of this photo is to show that MasterCraft can accommodate requests for custom seat configurations. This seat is destined for the competition arena and features extra body containment as well as side wings at the headrest for peerless lateral helmet restraint.
Our Baja RS seats were on...
Our Baja RS seats were on the operating table and Jose Gutierrez was our surgeon. Jose started by snipping the parachute cord to remove the seat cover. The old cord will be replaced upon re-assembly.
Since the Baja RS is a reclining...
Since the Baja RS is a reclining seat there were both upper and lower covers to remove.
Broken-down seat foam can...
Broken-down seat foam can be replaced by MasterCraft, making an old seat feel like new. Our seat foam was still in fine shape, so it stayed put. To install the adjustable lumbar support, Gutierrez pulled the foam away from the suspension liner along pre-cut lines, then sprayed some adhesive on in order to attach a backing strip for the lumbar support.
The backing strip is installed...
The backing strip is installed at a pre-determined height.
Here’s the adjustable lumbar...
Here’s the adjustable lumbar support mechanism. Made of spring steel, it cannot deflate, spring a leak, or dry rot. It offers up to three inches of additional lumbar support. The adjustment knob can be attached to the right or left side of the seat.
Jose rivets the fixed end...
Jose rivets the fixed end of the lumbar support in place.
A barrier strip goes between...
A barrier strip goes between the lumbar support and the seat foam.
Gutierrez inspected the parachute...
Gutierrez inspected the parachute cord tying the suspension liner to the frame. It was in fine shape so it was left in place. MasterCraft does not rely on the parachute cord to provide suspension in the seat. Suspension duties are handled by the suspension liner; the cord merely attaches the suspension liner to the frame.
Dual Pirelli rubber straps...
Dual Pirelli rubber straps give extra support in the tailbone area. These, too, were inspected and found to be in fine shape.
With the lumbar support in...
With the lumbar support in place and the foam, suspension liner, parachute cord, and Pirelli straps inspected, it was time for the new seat cover. The cord was temporarily taped to a skinny rod to make it easier to fish the cord through the cover’s attachment flaps.
The seat back’s cover was...
The seat back’s cover was eased into place and secured with a Velcro flap. Note the wires for the optional seat heater, a feature that’s perfect for cold weather or sore muscles.
Our Baja RS seats also featured...
Our Baja RS seats also featured optional adjustable headrests. The mounting sockets were tapped home with a soft mallet.
Camelbak water pouches were...
Camelbak water pouches were part of our initial order so they were added to the new seat covers. The adjustable headrests got new covers, too.
Before the seats were set back into the 4Runner, they had to pass muster under the watchful eye of quality control inspector Adam Martinez. Adam checked item after item off of an exhaustive list before he was satisfied. The final stop was the MasterCraft welding shop where foreman Gilbert Chacon and his crew re-installed the seats.