- Not much experience sewing vinyl and a home sewing machine.
- Fear that the pattern would have detracted from the overall look
- Concern that the ink on the vinyl might bleed upon interaction wtih sunscreen.
So I decided instead to go with Sunbrella fabric (found for $13/yd with free shipping, job required 5 yards) for it's durability, water resistance, UV protection. For my seats I'm using Glacier Blue with a Kiwi Green piping. Very simple, and hopefully not so light that every spec of dirt will show up.
Out with the old.
1. Demo the old seats, RETAIN the fabric, springs and frame. Discard old burlap, horsehair and cotton batting. Unfortunately these all had been home to numerous small furry friends over the decades.
|Zig Zag base spring, Cover with Burlap, Painted coil springs remounted with U nails|
|See how muslin is attached at|
center of seat?
There are many videos on sewing box cushions which is basically what these are minus the bottom. I particularly learned a lot from watching the upholstery videos from this fellow. Very easy to follow.
Here's one on how to make continuous bias cut welt-- for mine I used the same size as below and it was plenty. If you want more just stick to the proportions.
3. Cut foam and batting, upholster with muslin lining. I used 2 inch high quality foam called Everflex V44 (Density: 2.9 lb/ft3) guaranteed to last 15 yrs of regular use without dipping flattening or softening (so I suspect that will be much longer). I want these to last. (You can also do it the traditional way with cotton batting and horsehair/coco fiber instead of foam but it's actually more expensive. It was hard to find the fiber so I went with foam).
You will want to leave stretching/compressing to be done by the finish layer of fabric.
|muslin stretched and stapled to each piece|
4. Final layer of sunbrella fabric. First step, pull your muslin center pieces through and staple to the frame.
From here it's just a matter of pulling and stapling. Start with the center of the fabric and center of the frame on length and width. Don't pull too hard on the corners or you'll bend the foam down too far.
|Muslin which was sewn to the hinge of the cover|
gets stapled to each box frame
The finished products:
Cost of Materials
Sunbrella Fabric 5 yards at $12.95/yd $65
Muslin 6 yds @ 1.99/yd 12
Burlap 2.5 yds @1.49/yd 4
Dacron 10 yds @2.99/yd 30
Foam (ouch) 118
Pro Job for comp 700-800
savings ~ $500
Time probably about 6-10 hours
Sunbrella Fabric-- everywhere on line. Look for sales. I found a great deal at housefabric.com
Muslin, burlap, dacron widely available
Foam don't buy cheap foam it doesn't last. I like the folks at foamorder.com, and for me they happened to be local so I just went and picked it up.