With the same boards to work on, the costs were $1041. It included all new foam, plastic to seal, glue, and foam backed sheets in 1/8 and 1/4 inch. Foam, etc. was half, the covers were half.
If you have ANY mold, you need new foam and that stuff is expensive. It is ridiculously expensive right now for the good stuff.
Overall, I was surprised at how flexible the old glue was. The plywood was ok, and I used topside marine paint to coat it.
I bought an air staple gun just for this. I used stainless staples and double rowed all edges. The glue is made for foam/plastic/upholstry. It doesn't have over spray and has lots of solids to fill in rough spots.
The pull out seat in the back: Gone. It is a terrible seat and doesn't sit well anyway. I'll use my deck chairs back there and will turn the space into a locker. That will be great.
I was very pleased with the material and sewing job from Canvas Plus in Arlington, WA. Everything fit just fine and the stitches were all done well.
The re-assemble will take less than an hour. Nothing much to do there except a better job of caulking than the factory did. I have never recovered anything before, so it is doable if you go slow.
All installed. Went smoothly. Here is a photo of the dinette seats. Canvas plus was able to match the fabric after 10 years. I added an extra layer of batting to the front of the seats for extra support.
The foam that was replaced was cut at a company that does that. They used some kind of cold mold for some of it and just cut the rest. I used 1/8 and 1/4 foam to smooth out anything that looked like it would help.
Upholsterers also use a foam knife, which looks a lot like an electric knife with two blades. An electric knife will also work, but does not do as nice a job. I learned that if you make a mistake cutting the foam, just use spray glue, clue a hunk of foam back on the cushion and try again. It's not as easy as they make it look!
missrobyn, you make a good point, that's why i asked. i've tried a couple methods to cut foam. i'll give the electric knife a try. my best results came from frozen foam. simply got it wet and stuck it in the freezer to harden then cut with the table saw. that is only easy enough to do when the foam is small enough to fit the freezer.