Project #6: Make/Sew Outdoor Cushions

When it comes to outdoor furniture, the difference between relaxing and total comfort comes down to a nice cushion. When I started looking for cushions for my new outdoor furniture, I was disappointed by the selection. Some were too pricey. Some were too flimsy. Sizing seemed to be a problem, too. My custom-built chair, for instance, took a 24"x24" seat cushion. I couldn't find that size anywhere in local stores (or even online!).

Most cushions in stores were quite colorful, but just not what I envisioned for my neutral back porch. I'm trying to stick to a chocolate and tan color scheme so that I can easily throw in splashes of color on a whim, without breaking the bank.

• Here's our Cabot semi-transparent deck stain, in Cordovan Brown:
• Here's our rug from Home Depot:
  
• Here's a swatch (Rhino outdoor, khaki) of our curtains from http://www.fabric.com/:
  
• And I had already picked my inspiration "color" fabric for the time being. No introducing more colors or patterns than these (at least for now)! Here's the two coordinating fabrics (Richloom Coventry Spa and Covestripe Spa) we'll use--very sparingly--for throw pillows, from http://www.fabric.com/:
  

So you can see that patterned retail cushions were overwhelmingly TOO colorful for this purpose. (Maybe I'm just too picky or pre-planned?) And then some cushions had longevity concerns--do people really replace their cushions every year or two?!? Why would I spend that much money every year or two?

Well, being the project-craver that I am, I decided to make my own. After all, if you can't find exactly what you're looking for, just do it yourself. I ordered more Rhino khaki fabric, and started looking for foam. Foam is notorious for rotting, mildewing, and holding water--not what you want to hear when you're making outdoor cushions. So I opted to go with Nu-Foam, which is totally stain and mildew proof. The manufacturer recommends using this foam for boat cushions. I was sold. Luckily, my local cloth stores sold the foam by the yard. I was looking for 4" foam, but they only had 2" by the yard, so I purchased two slabs, cut them with an electric knife (a slightly laborious job), and glued them together. I also bought some extra thick batting to wrap the foam in to give it a little extra "cush." Nu-Foam is rather stiff, but seems to hold its shape well, so it just needed a tad extra help.

Next I set out to design my cushion. I didn't have a pattern. Instead, I sketched out what I was looking for: a square cushion with a zippered back so that I could remove, clean, or repair the cover (or contents) as needed. First, I made several yards of piping, using cording and 1-1/2" strips of fabric. Then, I cut one strip of fabric 22" long and 5" tall. I cut this in half length-wise and installed a 22" utility zipper. Next, I cut an 80" long and 5" tall piece that would wrap around the remaining sizes of the cushion and overlap (with ends folded under) the back zipper panel on each end (just to give it a finished look). Then I cut two large squares that were 25"x25" each. Finally, I sewed all the pieces together (5/8" seam allowance): top to sides (right sides together), with piping sandwiched in between, and then bottom to sides (right sides together), with piping sandwiched in between.

I was really pleased with the resulting cushions. They are exactly what I wanted. Though not quite as "cushy" as I would have ultimately liked, I know that these materials will last a long time and hold up to the weather that they will encounter while residing on my back porch.

These cushions went together quite well. Lining up the two squares is crucial, though, so that your cushion doesn't look slightly-twisted (a la an Oreo cookie)! Be sure to pin! I found ready-made 22"x22" square Nu-Foam cushions at the cloth store, which will make future electric knife episodes non existent. Plus, it will be cheaper, because I can use a coupon on each of these cushions, or buy them as they come on sale. I purchased my zippers on sale, and even got a great discount at Fabric.com when ordering my outdoor weather-proof fabric (plus free shipping on orders over $35). So all in all, I believe you could make each cushion for about $25 if you really stick to your guns and watch your spending. If that sounds steep, let me assure you that it paled in comparison to some cushions I perused at designer stores. And, I'd much rather pay a little more now to get a cushion that will last a while, with proper care. It took me one night to design my "pattern" and cut the fabric, and another night to sew two cushions! I'll call it a two-nighter.

What tricks and tips have you learned while making outdoor cushions? Can you recommend other materials that have worked well? How do you preserve your cushions so that you don't have to replace them every year? I'd love to hear/see your cushion stories!

Jennifer