My son-in-law asked me to make 16 cushions for the outside area of his wine tasting room. He bought the fabric ages ago, and I used some of it to recover the cushions on his own home patio. I have been putting off making the tasting room cushions because the weather has been too lousy for anyone to sit outside. But it is March now and I need to get this project done.
Like many projects that I don't do often there is a learning curve to get up to speed. I needed to figure out how to cut two-inch foam pads the size needed. I needed to refresh my memory on how to calculate the size of the gusset/box corners. And I needed to figure out how to do a zipper that wraps around the top two corners of the cushion covers for easy removal.
I spent half the day watching YouTube videos. Most of the instructions for making your own box cushions were horrible. One woman had her long hair hanging over the pieces she was demonstrating, so what she was doing was completely obscured. Not too useful. A couple of professional upholsterers recommended basting your seam allowance closed and sewing your zipper over it. Then removing your basting stitches, revealing the zipper, but leaving a gazillion little threads to pick off. No thanks, that sounds like extra work.
The most useful and easy to follow YouTube video was Steh Hiesher's DIY Easy One Piece Box Cushion Cover Tutorial. I highly recommend it if you have any cushion covers to make. Her method of making the boxed corners and the wrap around zipper were both great.
How about that zipper? It is a nice feature to have it wrap around the sides of the cushion. It makes it a lot less of a struggle to get the foam pad in and out for laundering.
Now this might surprise you. The foam cushions I am working with are two inches thick. My good Gingher scissors weren't right for the job, and the rotary cutter wouldn't work at all. After watching a couple of YouTube videos, the item that was recommended most often for cutting foam was an electric knife. My dad used to have one he used for carving the Thanksgiving turkey. I didn't want to touch it for fear of cutting off my fingers, but my husband is experienced with using one and he cut the first cushion for me.
One down and 15 to go! I tell you after making four cushion covers I am done for. Ryan has 16 seats he needs cushions for, so that is what I will be working on for the foreseeable future. I've got a system going now, so my pace should pick up!