Leather Reupholstery
It happened...my leather seat split open and as you can see, foam.

Does anyone have any repair suggestion, or a good source for re-upholstery kit that won't cost me an arm & a leg?

Is the Explorer/Mountaineer seat the same?

Unfortunately my 2002 interior color is Prairie tan, If it were gray I could probably find one easier in a junkyard.

Any junk yards around you, might be able to fine the whole seat pretty cheap? Just a thought

the seats are different in the explorer...i think they are bigger

If you have a location some where close, check these guys out: http://www.fibrenew.com/

I used them on two previous vehicles, and while the repairs were not 100% perfect (a close inspection could would reveal a fine edge of the crack), they did a very nice job. The cost was very minimal, and the repair was good for atleast 5 years (when I sold the car).

I dont recall the cost of the first one (it was quite a while back) but the Ion was torn about half as long and wide as yours appears to be, and I dont believe the repair cost exceeded $100 CAD.

I would definately give them a call, and let them take a look at it. I believe that they need to see it if the material around it is strong enough to support the patch.

It will give you an excuse to put some more miles on the HHO as well ;).