The next step is to locate an acceptable foam. The original black foam is 3/4\" thick so you need a 1/2\" fairly firm (higher density) foam. I located 1/4\" closed cell foam from my local auto upholstery supply shop. Ken used a softer 2nd layer as the outer most layer. That would be helpful when it comes time to fold over the skin and attach it to the plywood. I guess you could try some lower density 1/2\" foam. Then you take a 1/4\" thick piece of plywood. Cut the foam and the plywood to the correct shape. Use the white cover as a pattern. I found myself having to shave the plywood down several times in order to get a really good fit, sames true with the foam. The advantage of using 2 layers of foam is that one can be cut smaller to accommodate the curve in the cover.
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