Helinox Chair Zero

Two people have done this now and followed the same procedure.  Both times reading this thread I had the same question:  Why not just stick the golfball on the leg and then spray the foam into the gap?  I would think the foam would fill the ball nicely around the leg.  What is the advantage of the two step process of filling the ball and then drilling out the foam?

Ben – in a word, aesthetics :)

While your method is simpler and may lead to a better finished product, it is nearly impossible to gauge the amount of foam needed to fill the ball without it billowing out and all over the leg and workspace.  I had used foam in the past that stuck tenaciously and badly stained anything it touched.  Based on that experience I choose the method I documented.  Truth be told, the particular Dow foam I used on this project didn’t stick well and also didn’t seem to stain.  Another reason is that the hole in the ball will need to be enlarged enough to fit the fill tube…I chose to make the hole as small as possible.

I had planned to experiment with the process you described if I ever had to rebuild the feet.

Thank you for posting this, I had a couple of heavier 36 oz copy cats I bought from Sam’s Club last year for $30. They work great for car camping short hikes & events as well as kayaking picnics etc. To heavy to take backpacking though. So when an opportunity to recently pick up a Helinox Zero new/used for $50, I jumped on it. That said I’m going to do this for all three chairs! Thx again.

TOU