Make a removable bench cushion

Before you start

Tape paper together to make a full-size template and check it on the bench before cutting foam. Mark the front edge and check the area around hinges or arms. Decide whether the cover can be taken off easily once the cushion is in place and leave room for the envelope opening.

Tools and materials

• Large paper and tape for a template
• Upholstery foam
• Furnishing fabric and thread
• Sewing machine
• Tape measure, fabric scissors and suitable foam-cutting tool

Step-by-step instructions

1. 1

   Make a full-size seat template

   Press the paper into the back corners and mark the usable seat outline. Mark the front and test the template with the lid or arms in their normal position. Transfer the outline to the foam.

2. 2

   Cut the insert

   Support the foam on a flat work surface and cut along the marks with the foam tool, following its instructions. Test the fit on the bench.

3. 3

   Allow room for the foam thickness

   For a simple two-face envelope cover, start with the foam length plus its thickness and the width plus its thickness. Add your seam allowance on every outer edge. For example, 80 × 32 × 3 cm foam with 1 cm seams gives a starting front panel of 85 × 37 cm. Test on scrap if the foam is firm or the corners are irregular.

4. 4

   Sew the envelope cover

   Cut two back panels that overlap after their opening edges are hemmed. Lay them over the front with right sides together so the outside edges match. Clip and stitch around the perimeter, keeping the overlap flat.

5. 5

   Turn and fit the cushion

   Turn through the envelope opening and ease the foam in a little at a time. Line up the corners, smooth the overlap and test the cushion on the bench before adding any non-slip backing.

Check the result

Set the cushion on the bench and check that the insert lies flat without bowing the cover. Press along the front edge and corners. If the cushion bunches or the overlap gapes, check the fit before trimming the seam allowance or foam.