Alright, just throwing this up to complete the story for anyone in the furture who is experiencing seat issues. On Saturday I finally removed the seats from the car. What I discovered when I had the seats out on my familyroom floor sitting side by side was that my driver's seat was shot. It wasn't so much a poor design as a well abused seat. It still looked great (mint) but was a marshmallow compared to the passenger seat. The seat bottom and the lumbar support were shot, totally!
My first plan was to switch the seat hardware around just reverse the seats. Bad plan. What initially looked like identical seats with hardware just screwed/bolted on opposite sides, actually was different seat frames (both top backrest and bottom). Bummer.
I then stripped the upholstery about 80% off the seats (not as easy as everyone makes it out since the creases in the upholstery are held in place with bars and metal clips. I was able to pull it back enough to examine the foam cushion and come up with a second plan: re-cushion the seats. I thought I would leave the molded foam in place and just add some high-density foam to the weak spots, building them back up.
Sunday, after church, I ran out to the fabric store and bought some 1 and 2 inch high-density foam (50% off). I also bought some spray adhesive thinking I might need it. Returning home I started with the seat bottom and tried using different combinations of thinkness and shape in order to rebuild the bottom foam, while retaining its shape. I settled on two 1" think peices of foam of different dimentions to shape the bottom. I was able to reattach the upholstery of the seat bottom seat with the help of my wife. With her pushing down on the upholstery I was able to reattach the metal bars with wire and pull it tight. I was surprised by how good it looked. A touch poofy, but otherwise, stock. I was excited to sit in it, but soon discovered my utter failure! It made no difference! I sank right down through the seat again!
I spent the last part of Sunday coping with my failure and trying to come up with plan C. Upon further inspection noticed the springs on the lumbar section of the seat back (yet untouched) looked bent out of shape (but I had nothing compare it with since I hadn't disected the passenger seat yet, it still felt like new). I decided to sleep on the issue and come back in the morning (Monday was a holiday).
Monday morning I woke up with plan C: add firmness support to the springs. I decided that the seat bottom must also have shot springs (even though they looked fine) and all I needed was 1/2 inch particle board cut to the right shape and slid between the spring mechanism and original foam cushion. (This could be easily accomplished by unclipping two springs and sliding it in.) The Lumbar region I would tackle with a variety of sized pieces of 1/4 press board slid between the bottom two springs of the seatback and the foam cushion, again very easily done. I ended up with three pieces of pressboard, 2 measuring 12" x 6" and one measuring 8" x 6". I placed the 8 inch piece farthest away from the springs and closest to the foam. This seemed good, but I needed to wait until I had the seat all back together to tell. I then cut and slipped the bottom piece of wood under the seat and it too, felt more firrm. I rebuilt the seat and reattached the hardware and was ready for installation.
I decided to raise the driver's seat while I was at it and settled on using 1/2 inch wood spacers (from preasure treated scraps in my basement). With the new firmer seat, 1 1/2 inches left my head rubbing the headliner and even 3/4 seemed too high. I bought new bolts (an adventure in and of itself) and I was off. I reinstalled everything and sat down......
WOW!! It was awesome. I was so comfortable and the seat was forgiving yet very firm. the Lumbar support seems perfect! I was so pumped I had to go for my first test drive. It felt woderful and overall, I am very pleased. When I took my first turn, I found the only drawback to the whole thing. I left my foam in the seat bottom and I think it is a little too much. As I rounded that first corner I felt my butt rocking away from the turn and rolling a little off seat center. The bucket feeling is lost. I think if I had removed the foam I added and just went with the wood, I would have been better off. However, it is hard to tell now and WAY better than it has ever been since we owned that car. If it continues to bother me, I will take it apart again and remove the foam (maybe just one piece, maybe both) and see how it is. Anyway, after three days, I need my car back and I will take some trips and see how it is. Maybe the new foam will settle and everything will be alright anyway... we'll see.
Thanks for all your help and discussion,
Happy and comfy!