Build journal

The Strada CS.

In this Series, I document the development and creation of the Strada CS for my E46 M3 as part of the Bespoke Recaro seat program.

Enjoy,
- Matt

Strada CS ·Feb 05, 2025

From design to canvas

by Matt Di Vita

"In this entry, we cut into the original Sportster CS foam and fill in other sections to set the foundation for the new covers."
- Matt

Creating separation.

During the study and re-creation process of the original BMW Performance seats, we understood any significant changes to the design patterns of covers required matching modifications to the underlying foam.

In the entry "The foam makeover begins.", I documented the process to re-creating the signature ribs.

Foam work is about cutting new lines, filling in those we no longer require and repairing any foam imperfections from Recaro's mass production processes.

Within these new lines, clips and velcros are added to firmly pull the cover into the creases. It eliminates wrinkles, loose sections and enhances the aesthetics of the seats.

The differences between a cover with and without foam work are difficult to notice on social media posts. Once you know what to look for, you will notice the discerning quality details to a properly customized cover and foam.

Foam work is in-depth artisanry that you will never see. Yet, it creates separation from the most popular sources of BMW customized seats I have personally witnessed.

Ultimately, your dream set of Bespoke Recaro seats are made to sit in - in real life! How they feel and how they appear will matter most to you.

From design to canvas.

The Strada design creates two new center sections and blends in the ribbed upper middle section. Consequently, it requires cutting two new lines into the foam and filling in three lines from the original design.

Recaro had four cut lines with velcros to stretch the cover in order to create the 3x ribs, the middle rib was use to showcase the Recaro branding. The Strada design simplifies the middle the middle section, retaining only a single cut line that will connect the crown to the headrest section.

The first step to the process is tracing the new sections directly on the foams. To do so, we used the original Recaro sections that were previously cut according to our Strada design. Each section is carefully aligned according to the previously marked reference points from the original covers and the clips within the foam.

We further identified the shape of the foam to be filled and blended.

The new cut line on the lower section is far simpler: it's straight! Still, it isn't easy as it looks - it will be understood prior to the foam cutting step.

Mass production.

Recaro's mass production processes aren't perfect, their quality control allows some level of imperfections in the foam. Prior to any foam work, we inspect the original foams and identify areas to be repaired.

Below are 2x examples, with one being most concerning to us. The foam was thinner near the upper line of the Strada design. We marked this specific section and planned repairs. It will ensure proper aesthetics of the cover and long term durability.

From canvas to reality.

At the foam cutting step, mistakes get expensive - if we damage and compromise the foam, we need to buy a new set from Recaro. We thus mesure thrice, and do our best to cut once.

We start with evaluating and measuring the required depth and widths of each new line, comparing with the orignal lines in the foam. There are varying withs and depths across the foam that need to be considered in the process.

Reference markers.

We use measurement markers on the cutting tools and foams for a visual reference. On the dremel, the tape references the maximum depth of a specific cut. On the form, we add new parallel lines to the previously traced outlines.

Both markers act as our guardrails during the cutting process, helping cut true and straight.

With all measurements counter validated, we proceed with cutting in the foam. It's a relatively fast process with steady hands and confidence established from the visual markers.

Recaro's foam imperfection became a problem during the cutting process. The thinner section was caught in the dremel's blade, separating from the foam. This further explains why we didn't perform any repairs prior to the cutting step.

Repairs.

We first repaired the previously shown foam defect. We shaped and glued new foam, along with sealing it in for durability.

We then performed repairs on a small section of the original Recaro velcro that had unglued during the cover's removal process. Such minute damage is why we view selling Sportster CS covers on their own is risky, and choose not to.

Velcros.

With the foam cut and repaired, we now proceeded with gluing in new velcro strips. Velcro is a generalized brand name for a hook and loop fastener. It's commonly use for fabrics and it is relatively strong, and allows for repeated use.

As per the original Recaro methodology, the hook goes on the foam and the loop on the underside of the covers.

Filling and blending.

The last significant step to the foam rework is to fill in the upper middle section. At first flange, it seems simple enough- careful attention to details is always required.

The original foam had velcros glued within each line. Steam was used to undo the adhesive bond and the velcro were slowly pulled away to avoid damaging the foam. As this foam area is the thinnest, risks of piercing through were higher than other sections.

The next step was to cut stripes of bonded foam. The widths were measured to match whereas the length was slightly more than appeared required. This is done on purpose as this foam section has varying heights for precise fitment of the harness slot covers.

The protruding foam stripes would be cut to match the varying heights and retain the original fit and finish. We retain a single original Recaro line that connects the headrest section with the "crown" section of the Strada design

The last step is to glue and seal in the newly created sections for durability and aesthetics. The process connects foam pieces together to create two seamless sections upon which the Strada cover will lay.