How to Make a Powerboat Aft Bench Cushion

Item # X-HT-200706

Does your powerboat have hinged bench cushions with hidden storage underneath? This is a pretty common arrangement and our Powerboat Makeover is no exception. The aft seating on the bridge deck on this 1982 Regal 245 XL Ambassador is made up of a hinged bench cushion with storage underneath and an upholstered backrest that is attached to the stern rail. We recovered all of the seating on the boat’s bridge deck and in this video we’ll show you how to recover the aft bench cushion. The process for recovering the backrest can be seen in a companion video (#200705XHT).

Aft Bench Cushion Before and After.

This bench cushion is made of foam and a vinyl cover stapled to a backer board. Hinges install into the board so the seat can be tipped back for storage access. To recover the cushion we removed all the old fabric and foam, cut new foam and sewed a decorative top. The vinyl cushion cover was made to match the color scheme we chose for all the seating on deck: a channeling fabric in Lite Glacier and traditional vinyl in Stinger Bisque and Midnight.

To create a clean appearance, we also decided to upholster the underside of the seat, since you can see it when the storage compartment is opened. For this we used Phifertex® Mesh, which gives a clean appearance and allows breathability. To hide the staples used in upholstering the seat top, we installed Hidem Gimp trim where the vinyl met the mesh.

In this video you will learn how to pattern, cut and glue foam; sew a decorative top plate; add piping; assemble the vinyl cover; staple the cover in place; and hide the staples.

Video Chapters:

  • Removing Old Upholstered Fabric – 0:54 min.
  • Patterning & Cutting New Foam – 3:44 min.
  • Patterning Top Plate Sections – 6:00 min.
  • Sewing French Seam – 11:01 min.
  • Sewing Channeling Fabric – 15:03 min.
  • Sewing Prefabricated Piping – 20:35 min.
  • Making & Sewing Boxing – 23:38 min.
  • Preparing the Backer Board & Installing the Cover – 30:14 min.
  • Hiding Staples – 36:16 min.
  • Materials List – 38:54 min.

Materials List:

  • Cushion Wrap Silk Film #103933
  • High Density Polyurethane Foam (Firm) 3" x 24" x 82" #120195
  • Dura Skrim® Patterning Material #103134 (optional-for decorative patterning only)
  • Marine Vinyl Fabric (we used Morbern® Seabrook Stinger Bisque #105978 & Midnight #105987)
  • Marine Vinyl Channeling Fabric (we used Morbern® Seabrook Lite Glacier #105994)
  • Grosgrain Polyester Binding (we used Beige #105423)
  • Seamstick 1/4" Basting Tape for Canvas #104167
  • Seabrook Vinyl Welting/Piping (we used Midnight #120144)
  • Phifertex® Vinyl Mesh (we used White #393) or Cushion Underlining Fabric
  • Sailrite® 21 Gauge 1/2" (12mm) Staples 10,000/Box (Stainless) #8012SS
  • Polyurethane Foam 1/4" With Fabric Backing 60" #105432
  • Seabrook 3/4" Hidem Gimp (we used Lite Glacier #120132)

Tool List:

  • Tack & Staple Remover #104319
  • 3M™ General Trim Adhesive #73211
  • Clear Acrylic Ruler 6" x 24" #102400
  • Gingher® Scissors Right Handed #19104
  • Sewing Gauge Ruler 6" #102995
  • Magnetic Sewing Guide #102983
  • Sailrite® Ultrafeed® LS-1 PLUS Walking Foot Sewing Machine #300502
  • Gingher® Thread Nippers 4 1/2" # 04710
  • Sailrite® Long Nose Upholstery Staple Gun #121411
  • Drill & drill bits
  • Foam cutter or electric kitchen knife
  • Marker
  • Masking tape
  • Pencil
  • Tape measure