foam – SewingMachinesPlus.com Blog

My husband and I sleep on a full-sized bed on 4” of high density foam that we bought from Keyston Brothers, a store that specializes in auto and marine foam and fabric (We use density type Q41 for anyone interested in doing the same). We find the foam lasts about five years before we need to replace it and for a full-sized mattress’ worth, it costs about $250. That is loads cheaper than a fancy mattress and we sleep like babies.

Sweet dreams!

We discovered this foam when we were replacing the cushions in the v-berth of our sailboat. We lived aboard for almost eight years and slept amazingly. When we moved on land we decided to cut costs and stick with the foam. I made a custom cover for it but this frame we recently got from Ikea is smaller than the foam. See how it curves down into the bed and up and over the edges? My husband and I were getting rolled into each other at night so I knew I was going to have to take matters into my own hands.

See how it curves down into the bed and up and over the edges?

Let’s get started

I took off the cover I had made and measured the foam to a size that would fit in the frame. Then I got out my $20 electric cutting knife from Walmart and got to slicing.

Take a deep breath. We’re about to slice into our bed. Ready? Let’s go!

Upstairs, I cut the side piece (zipper piece) off of the top and bottom of the cover. Here are the two main panels laid out.

Here are the two main panels laid out.

Zipper time!

I had finished all my seams with zigzag stitches and there was no way I wanted to take out all those stitches. Instead I saved the zipper by just taking out the straight stitches holding it to the cover.

I saved the zipper by just taking out the straight stitches holding it to the cover.

Zipper saved! Now I didn’t have to buy another one for the smaller sized cover.

Zipper saved!

Let’s sketch this out…

Math time! Here I had to work out the new size of the zipper plaque and the rest of the side facing. Plus I wanted to add handles this time so I measured out those too. I also cut the top and back panels to the same size as the foam that now fit in the bed frame.

Math time!

I was all out of the original fabric I had used to make the mattress cover so I used some leftover Sunbrella scraps I had from another project. Here are the parts I’ll need to piece together for the zipper plaque, the rest of the sides and the handles.

Here are the parts I’ll need to piece together for the zipper plaque, the rest of the sides, & the handles.

I made quick work of the four handles and top stitched them for strength. The ends are unfinished as they’ll be sewn inside the cover.

I made quick work of the four handles & top stitched them for strength.

Next I sewed the zipper plaque and side pieces together. I also made sure to zig zag stitch each join to prevent the fabric unraveling.

Next I sewed the zipper plaque & side pieces together.

Making the zipper plaque is my favorite part. It means I’m getting close to being done. Here I’ve switched to a zipper foot so I can get super close to the zipper.

Making the zipper plaque is my favorite part.

Next I sewed on the handles to one of the large panels.

Side facing

Now it was time to add on the side facing. Yes! I joined one end of the side panel to the zipper plaque and started sewing on the zipper plaque portion first. Then I just transitioned to the side piece and kept going all the way around.

Now it was time to add on the side facing.

I stopped several inches before I got back around to the beginning and joined the two ends. Then I trimmed off the excess, zig zag stitched the join, and then sewed that piece onto the bottom panel completely.

I stopped several inches before I got back around to the beginning & joined the two ends.

Pro tip: make sure you open up your zipper enough right now that you can get your hand through it to open it completely when turn this right sides out in a few more steps.

You are so close now!!!

Before you begin sewing on the top panel there are still two important things you need to do.

Create match up marks.

Create match up marks. When you are working with large pieces of fabric, things have a tendency to shift. These marks will let you know you are joining the two pieces together where you should. If you look carefully you will see pink marks on either side of the fabric at the 19” mark. I marked the side pieces and then the top piece so everything should match up when I sew.
Do your corners!!! This is crucial. Go to each corner and fold it down and back until you are sure the piece is square with each side. Then mark that spot so you know you’re at the actual corner when you get there.

Do your corners!!!

Begin sewing your final panel to the cover. I like to put the panel that is being sewn on the bottom. Here you can see I’ve matched my corners perfectly.

Here you can see I’ve matched my corners perfectly.

When you’ve sewn all the way around you are ALMOST done but not quite. There are two things to be done first.

Take the time to carefully inspect ALL seams, fronts and backs. Sew anything you might need to.
Then you need to zigzag stitch both seams in order prevent the fabric from unraveling.

You may think you have finished the hardest part, but the worst is yet to come.

Pat yourself on the back

You may think you have finished the hardest part, but the worst is yet to come. It’s time for cushion Olympics. Yes, wrangling foam into cushions should be an Olympic sport.

Here’s what you need to know:

Go slowly. Do not pull the fabric or you will rip your seams and pop your zippers.
Rather, walk the foam into the cover. I like to fold it on the ends and walk it a little sideways.
Patience, patience, patience. Fit your foam into the pattern just the way you designed it. It you did your math right, it WILL fit.

Go slowly.

After burning some calories (always a good thing), you will have your new mattress with custom fitting mattress cover that actually fits into your bed frame. Now you may rejoice.

Now you may rejoice.

Look at those clean lines!

Do you make your own bedding, including mattresses? We’d love to hear about your work.

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Charlotte Kaufman is a writer and sewist in Mammoth Lakes, California. She specializes in marine and home interiors and continues to fall more and more in love with quilting. You can follow her at charlottekaufman.com.

DIY chair cushions for kids.

I’ve been wanting to make cushions for the art table chairs in our girls’ room for a while and I finally made it down to a craft store that sold foam this week to get started on the project.

The first step in making custom cushions is accurate measurements. Notice how the chairs are not true squares? The front measurement was 13” and the back 12”. The distance between the front and back was 11 ¼”.

The first step in making custom cushions is accurate measurements.

Want to know a trick with cushions? Cut your fabric to the exact size of the foam. I know this sounds counter-intuitive. ‘But what about seam allowance?’ you’re thinking. The thing is, foam compresses. If you cut your fabric to the size of the foam, and then sew ¼” seams (or ½” if using heavier duty fabric), the compression of the foam once it is in the cushion cover will more than cover the seam allowance you are used to providing on other sewing projects.

Want to know a trick with cushions? Cut your fabric to the exact size of the foam.

I’m trying to use up my fabric scraps this year, so I pulled out a few larger, odd-shaped scraps I had from this fabric and was able to cut out four top and bottom panels for the two chairs.

I’m trying to use up my fabric scraps this year, so I pulled out a few larger, odd-shaped scraps.

I used this fabric to make custom piping for a bench seat for the girls’ godmother. I like that they’ll have a small piece of the project I made for her in their own room. See the pink trim on the cushion below? That’s the same fabric.

See the pink trim on this cushion? That’s the same fabric.

For the side panels I decided to use corduroy from an old pair of pants I’d been saving for just this kind of project. They’d developed holes along the belt loops so I had held onto them just for the pretty fabric.

For the side panels I decided to use corduroy from an old pair of pants I’d been saving for just this kind of project.

After marking the measurements with a Sharpie, I used an electric bread knife to cut the foam. It cuts through that stuff like butter. Here’s a gif as proof.

My electric bread knife cuts through the foam like butter.

Another make-your-cushions-super-great secret is to use batting!! Wrapping them in batting or putting a layer on the top and bottom will improve how the puff up in your cushion covers. I used an adhesive spray to affix the batting to the top and bottom of each one.

I used an adhesive spray to affix the batting to the top and bottom of each one.

Don’t measure the height of your sides until you’ve added batting. While the foam is 2”, adding the batting made the total measurement just under 2 ¼” (I should know what that measurement is, but I don’t. I just mark to the line under that ¼”).

While the foam is 2”, adding the batting made the total measurement just under 2 ¼”.

Grab your zippers and zipper pulls, or, if you aren’t like me with spares on hand, plan ahead and order them before you begin.

Grab your zippers and zipper pulls!

I like to sew the zipper plaques first. Use whichever technique you like. I generally use the first method shown in this video by Sailrite.

I like to sew the zipper plaques first.

If you need to attach extra fabric to the side panels, consider adding it to the ends in small amounts so the joins don’t show on the front of the cushion.

If you need to attach extra fabric to the side panels, consider adding it to the ends in small amounts.

Attach the zipper plaque to the side fabric and then sew onto the bottom fabric piece.

Before you begin sewing the top piece on, make sure to mark your corners accurately. Fold them to each seam to make sure they match (the yellow mark in the photo below is my matching point.)

Fold the corners to each seam to make sure they match (the yellow mark in the photo below is my matching point).

Next, make sure to slide on the zipper pulls BEFORE you sew the top piece onto the final assembly or you’ll be sad.

And finally, do not forget to sew your tie backs in between the seams as you go.

Do not forget to sew your tie backs in between the seams as you go.

Whoohoo, you’re done! But, before you start celebrating, go over every seam to make sure they are secure.

Whoohoo, you’re done! Now, go over every seam to make sure they are secure.

Then take your scissors and round the corners so they turn prettier. I used pinking shears on the fabrics in this project. Check out my post from January to learn about their benefits, along with other important cutting tools for your sewing room.

Take your scissors and round the corners so they turn prettier.

When you turn the covers right-sides out, use your fingers to pop out each corner.

If you’ve done this right, your finished cover is going to look smaller than your foam; that’s because it is! Now is the time to put the cover on the cushion and here is where you’ll see how foam compresses to fit your new cover.

Now is the time to put the cover on the cushion & here is where you’ll see how foam compresses to fit your new cover.

I’m going to use caps lock here to get across how important this next step is: DO NOT TUG OR PULL ON YOUR FABRIC TO GET IT ONTO YOUR CUSHION. I promise you, if you do that, your seams will pop. Instead, fold the cushion to slide it into the cover, and then slowly work the foam into the fabric, NOT the other way around. Just keep thinking ‘move the foam, not the fabric.’ Don’t be afraid to really get your hands deep into the cover and use them to maneuver the foam in place. Adjust, adjust, and adjust, until the cushion sits perfectly in the cover, with the lines of the foam matching the lines of the cover.

DO NOT TUG OR PULL ON YOUR FABRIC TO GET IT ONTO YOUR CUSHION!!!

Ta-da!!!

Ta-da!

This project turned out just darling. The corduroy almost looks like velvet and I love the effeminate touch it brings to the room.

The corduroy almost looks like velvet and I love the effeminate touch it brings to the room.

These cushions will inevitably get marks on them. That’s okay, they have zippers so they can be washed, AND, they are reversible. I can just flip them over if I need to.

I can just flip them over if I need to.

My daughters loved these and immediately hopped on and got cozy.

What DIY projects have you made for your home lately? Let us know in comments!