Patent ID: 6848156

Claim:
A method for making a motorcycle seatback with an aperture extending therethrough comprising: (a) providing a mold having a base with a cavity providing the desired peripheral configuration for the backrest and an upstanding post centrally thereof, and a channel extending through the side wall of the mold from said cavity to the exterior of the mold; (b) introducing into said cavity a first deposit of a resin formulation; (c) placing on said first deposit of said resin formulation one end of a rigid frame member having a post extending outwardly of said mold cavity through said channel and having arms laterally extending to opposite sides of said post; (d) introducing a second deposit of a resin formulation into said cavity over an upper end of said rigid frame member to bond with said first deposit and encapsulate said upper end between said deposits; (e) at least partially curing said resin formulations of said first and second deposits to provide a rigid synthetic resin base; (f) introducing a cushion resin formulation into said mold cavity over said at least partially cured resin of said first and second deposits, said cusion resin formulation being curable into a resiliently deflectable cushion layer; (g) curing said cushion resin formulation to provide a seatback structure with an aperture extending therethrough and said post depending therefrom; (h) removing said seatback structure from said mold; (i) forming a flexible cover over the surface of said cushion layer of said seatback structure and about an outer periphery of said seatback structure and through said aperature; (j) securing said cover to an opposite surface of said seatback structure; and (k) securing to said opposite surface a cover plate having an opening extending therethrough aligned with said apartures in said seatback structure.