Let's Make a Cushion

Let's make this

 I have a pretty crappy desk chair. It's really a dining chair. This is how I made a custom-fit cushion for it using materials I had on hand. I won't say it's the correct or best method but I did make a very decent looking cushion in 10 steps.

Three Points of Interest: 

•  I used to have one of those terrible egg crate-style mattress pads that I nabbed from my late grandmother's old house a few years ago. I remember my grandparents being particularly impressed and devoted to egg crate stuff -- they also had pillows. The one I got was brand-new, never-been-opened. I'd been using it for about two years. (It was the most pathetic thing to put on top of a mattress.)

The other day I thought I'd wash it.  I had done this in the past with great success but I forgot to use a low setting in the dryer and a hole burned out of the center. This is what I used for the foam in my chair cushion.

•  My sewing machine is on the fritz so I'm going to sew the cover by hand.

•  The cushion I'm going to make consists of a layered foam core and a zippered cover with ties.

•  Wash and press your fabric before sewing.

Materials
Upholstery or other sturdy fabric
Upholstery thread
Upholstery or other heavy duty needle
Zipper (~18")
Scissors
Paper
Ruler
Markers
Straight pins

Step 1: First I created a pattern based on the shape of the seat of the chair. I did this by using a large sheet of paper and tracing the shape of the seat in two sections, cleaning up the edges, and piecing the two parts together. I took that base shape and added 0.5" allowance. This creates the pattern for the cover.

Step 2: I retraced the seat shape to create a pattern for the foam. I traced the pattern on to the foam with Sharpie and cut out 6 layers.


Step 3: Determine how thick you need the gusset to be. I want a 4" deep cushion so I made a 5" gusset pattern piece (the zippered portion will need to be 5.5"). I divided my gusset into two parts: the zippered section that goes around the back curve and the longer portion that will go around the front and sides of the cushion. Use a measuring tape to determine the length you need and add 1".

Step 4: I created the zippered portion first. Cut the strip in half and stitch in the zipper using upholstery thread (which is used throughout this project).

Step 5: Using the cover pattern, cut two pieces of fabric to create the top and bottom of the cover.

Step 6: Find the center of the cover pieces and longer gusset piece and pin together. Stitch the pieces together. Pin on the zippered portion. 

Step 7: Unzip the zipper about 3" (this will make it easier to unzip from the reverse side).  Sew the sides to the top and bottom.  Unzip and turn it right-side-out. Insert cushion. If you use layers, it's easier to insert one layer at a time.

Step 8: Using a strip of fabric about 30" long and 2" wide, press the fabric to make the ties: Fold the fabric in half and press. hen unfold and refold each half in half and press. Fold the halves together and stitch closed. I used blanket stitch. (Confused? That's okay. You're basically making something like bias tape.)

Step 9: I want a contrasting finish so used straight stitch along the top and bottom seam. This will also also reinforce my inner stitching since I used straight stitch.

Step 10: Fold each tie in half and sew into the corner. Stitch the gap closed. I used a matching thread and hidden stitch.

 Ta da!