Sofa Gets Six New Box Cushions

Updated, New Foam w/Tweed Fabric

Outdated Fabric,
Saggy Cushion

If you’ve lived through the 1970’s, you’ll likely have owned or knew someone who owned a sofa with fabric that looked similar to the one on the left. I refer to this as “Brady Bunch” fabric, the popular rust, tan and brown used on the show along with bright orange, green and yellow tones. My parents had a similar style sofa and chair in their living room, but with more green and a smaller plaid than this one. Since the 1970’s, fabrics have changed and we have so many more options in the twenty-first century than we did in the 1970’s. The sofa had a total of six cushions, three seat and three accompanying back cushions.

The original covers had a center seam style with a single row of piping which surrounded the top and bottom seat, along with a rear metal zipper. Modern box cushions are constructed with a top, a bottom and a center “boxing” which includes a zipper placket. The best technique to make these box cushions is to measure the size of the foam and allow at least 5/8” seam allowance for each side. These cushions needed new foam which was 6”, so it was necessary to allow a 7-1/2” zipper placket and a 6-1/2” surround, which is sewn to the completed placket. If all seams are sewn properly and accurately, both fabric sections should line up for a nice, even continuous side boxing. 

For these cushions, it was easier to make the top and bottom portions, adding the piping to each one, then stitching the zipper placket in place using clips, which are easy to move when you’re fitting the placket to the top and bottom fabric. A piping foot is an essential tool for this project. Piping (also known as welting or cording) is comprised of a tightly wrapped polyester cord commonly used in upholstery projects as an insert, for a customized, decorative edge. In apparel, it can be used as a décor item or trim. Piping comes in various thicknesses for different applications. 

These were six loose cushions used on a wood-framed sofa. The foam itself had severely deteriorated (as 50 year old foam will) and was crumbling inside the fabric, leaving a fine, yellow powdery residue. Surprisingly the fabric was not torn or damaged, but was very loose and saggy, due to the cushion no longer holding its shape as a result of shrunken, deteriorated foam. Therefore six new foam cushions was a must, as well as new fabric. If you’re going to invest in new fabric, it’s recommended to get new foam to get the maximum comfort and longest wear. However, if your cushions are still in good shape, they can be used with new fabric. All new foam is then wrapped in Dacron for a nice crown and better shaping.

The customer chose a lovely gray tweed interspersed with off white, nicely woven into the gray. The color combination was great and the fabric was easy to work with, despite it being relatively heavy upholstery material. The stitches were practically invisible (always a bonus) therefore the cushions came together beautifully. They should last many years and provide comfort and support to all who sit on them.