Looking for a budget friendly source for foam for my 68 442 buckets. I don't car about grooves that work with factory style covers as I'm not getting upholstered factory style. It seem like what can separate these foams is grooves and no grooves? Any input is appreciated! I did go to the recommended site but nearly $400 for the foam is a bit steep, especially when it seem to be Chevy comparables out there at 1/2 the price. I just don't know what Chevys I can use.

 

Go to Thorntonmusclecars.com

They make the best seat foams as far as I'm concerned and the price is nowhere near what you mention. You can get smooth or slotted----your choice.

 

If you are spending the money on custom upholstery, don't use cheap foam.

 

I used to only recommend the ACI stuff after issues with most of the other ones available- but after using the Thornton's stuff for the first time last year, I've changed my tune.

The ACI buns *ARE* better quality, but with the Thornton at half the price, and is still SOFT like the ACI buns and originals (the PUI, TMI and other repop buns are way too hard) they feel just as good.
I literally have another set of Thornton buns sitting next to my work bench ready to go on another set of seats I'm building.

I did a side by side comparison/review a year ago with pics, they are in this forum if you scroll back a ways.
The primary difference is the ACI ones are a "cleaner" look of the raw bun, where the Thornton has lots of foam "slag" left on it... But none of that impacts the way they look or feel after they are installed.
ACI buns come with muslin "attaching" cloths glued to them, which are needed for installing the buns (same as OE). Thornton buns do not have the attaching cloths, BUT they are molded a little different with "lips" on the sides so they stay on by themselves while installing. Or if you want to just glue on some muslin or canvas strips to hold them in place its a small expense/hassle to do for the cost savings.

The only ISSUE that i had with them was the upper cushion buns lower lip didn't quite extend downward as far as i would like... So i wound up adding a strip of 1" foam across the bottom to help protect where they wrap around the bottom edge of the top cushion. Also not "NEEDED" just something I did.

 

funny, I guess I never posted it here... Here it is from the pontiac board: Thornton Restorations 66-72 Seat Buns Unboxing/Review