@tig said: ...on a side issue... ... and even a lone RB can be made into a ZIP and then that .zip file re-suffixed with .rbzso that it can be auto-installed... Thank you, TIG - this is great information. Won't add rb directly to the Tools folder anymore.

Is this for visuals or production? If you're trying to make a seat for a tool I think Dave's process would work great. For fun, you might try an app like this http://blenderartists.org/forum/showthread.php?319906-Turn-your-Android-Phone-into-a-3D-scanner-with-this-app on your phone to get the geometry.