What is everyone using for side rail foam? I'll probably be making the covers myself, for the foam, out of cordura. I was wondering what would work best in the way of the foam. Pool noodles? Pipe Insulation? Anything to look for specifically?

I don't buggy, but a couple people I've spoken too like the pool noodles. They are cheap, easily available, and actually comfy. I sat in my buddy Rob's homemade buggy and he used pool noodles. It was quite comfy, and there's a multitude of colors to choose from too!

I see you are located in Ohio. I don't know how close he is to you, but Chip and his father George live there and they buggy. So you might want to give them a U2U. Chip on PKF is.......well Chip. For the moment I can't remeber George's but someone will offer it up if I don't remember first.

Another option is Pipe Insulation foam found at most hardware stores such as Home Depot, Lowes, or Menards. I like the pipe foam better than the noodles because you can get it with self-sticky tape that will help hold the foam to the bars and it is pre-slit down the center. Colors are usually only gray or black. No problem if your going to cover it up with a cover anyways.

Cost is usually around 2-3 bucks for a 5 foot length. Usually more than enough to do one buggy.

I chose the pipe insulation because I had it. I think that Pool Noodles would do the job much better. Both for comfort and safety. I would think that if I took it in the face or a similar hit that the noodle would cause far less damage. The pipe insulation feels better than steel but I'm not sold on it.

Pool noodles work great. Just cut a slit down the lenght. Once you have it on the tubing get some duck tape and wrap the noodle form end to end. You can use different size noodles to snug you in the seat. I have used noodles for all my buggys and they have held up now for several years.

Susan