I found the Backjoy to by quite comfortable and decided to copy it in carbon fiber.

First, I purchased a Backjoy that came with a lot of holes in it. Then to make a mold, I covered it with packing tape but the tape just did not stick down to my satisfaction. Then I tried masking tape, which worked much better. It took quite a bit of tape to cover all of holes I waxed the masking tape with mold release, and applied three layers of chopped mat glass with polyester resin. The Backjoy is flexible, hence getting it off the mold was not too difficult.

I then built a frame of plywood and cardboard and filled the voids and created a 3 inch flange, with 2 lb urethane foam.

It the flange was glassed with epoxy resin, filled and sanded. Several coats of epoxy with fairing filler and some sanding and it was ready for use. Three coats of wax mold release. there is a layer of carbon fiber and two of chopped mat and it was vacuum bagged.

More to come.