SUPPLIES & TOOLS:
DIRECTIONS:
- 1/4" Plywood (for backing)
- 1" - 2" Cushion Foam (2" used in image)
- Low Loft Polyester Batting
- Outdoor Canvas
- High Performance Loctite Spray Adhesive
- Utility Knife or Bandsaw
- Electric Knife or Bandsaw
- Scissors
- Jigsaw
- Tape Measure
- Ruler
- Marking Pen or Pencil
- 1/2" Cardboard Strips
- Hot Glue Gun/Glue Gun Sticks
- Staple Gun & Staples
- Rotary Cutter & Cutting Board
- Iron & Ironing Board
- Spray area
DIRECTIONS:
- Measure size for cushion. Cut 1/4" plywood backing panel to size. Divide width of wood backing into equal sections to determine number of panels. On wood, mark width of panels, (channel locations), with a line from the top to the bottom of the wood. Use a utility knife or Bandsaw to cut 1/2" widths of cardboard. Hot glue cardboard to wood at channel locations. Use an electric knife or Bandsaw to cut widths of foam the width of the panels. Cut the length the height of the backing board.
- Start with the second panel from the side of the backing. Spray adhesive to one side of a foam panel. Press in place between the channel lines, settling the edges of foam between the cardboard strips. Cut a width of batting to cover foam. Cut width to run 1" past the cardboard strips on either side of the foam panel. Cut height to run the height of the backing panel plus enough to wrap around onto the back of the backing panel by 2" at the top and the bottom. Spray adhesive to one side of the batting and center over the foam panel. Cut fabric to the same size as the batting. Lay the fabric right sides up on top of the batting. Staple the fabric and batting into the cardboard strips. Pull fabric taut and staple either side close to the top and bottom of wood panel. Once satisfied that the fabric lays smooth add additional staples close to one another down both cardboard strips.
- Cut enough batting and fabric to cover all center panels. Add additional width to the two outer panels to run the batting and fabric 2" around to the back of the wood panel.
- Apply an adjacent middle panel. Lay the second fabric panel right sides together on top of the first covered panel. Staple the edge onto the cardboard strip. Layer a cardboard strip on top. Staple in place. This will create a clean straight line in the channel between panels. Spray adhesive to one side of a foam panel. Press in place between the channel lines. Spray adhesive to one side of the batting. Press on top of the foam with enough batting to run down the fabric side of the foam panel. Settle batting down the side. Flip the free edge of fabric over the batting. Feel for the cardboard strip. Staple batting and fabric along the cardboard. Repeat. For end boards pull the batting and fabric around to the back of the wood and staple.
- Finish the top and bottom edges. Create two folds front to back, one on either side of the foam panel. Start with the batting. Cut away excess batting at folds to reduce bulk. Staple to the back of the wood 1" from the edge. Repeat for the fabric. Do not overlap the folds from one panel to the next. Trim away any excess fabric beyond the staples.
- Back cover. Cut fabric to the size of the backing board. On the wrong sides of fabric, mark a line 1" in from all edges. Hot glue 1/2" strips of cardboard lining up the inner edge of cardboard with the line. Apply hot glue to the 1/2" edge of fabric outside of the cardboard. Wrap fabric around cardboard. Set cushion wood side up. Center the fabric right sides up on top of the wood. Apply the fabric to the wood with a small bead of hot glue under the cardboard strips.