How to Sew Sofa Cushions

Item # X-HT-300411

If you have a sofa that is still in great condition but the cushions are looking a bit worse for wear, don’t buy a new one! Why not reupholster your existing sofa cushions in a new, more stylish fabric? In this tutorial video, we’re going to show you how to sew new sofa cushions for a sofa bed using stylish Sunbrella® Upholstery Fabric. It’s easier than you think!

Newly upholstered sofa cushions.

Sofa cushions vary both in style and design. The cushions on our couch have a bullnose front. This means that the top and bottom of the cushion is one piece of fabric that is wrapped around the front of the cushion. A boxing or band is then sewn to the sides. The zipper is installed at the back edge of the cushion for inserting the foam. This is a fairly easy design to replicate, and our seamstress, Cindi, will show you how it’s done.

In this video tutorial, you’ll learn how to disassemble the current cushion panel and use it to pattern your new fabric. You’ll learn how to sew fabric tucks at the forward edge. Tucks or pleats give your bullnose cushion shape, and they also provide a stylish, decorative accent. You’ll also learn how to sew the cushion plate and boxing together and install the zipper plaque. Our step-by-step video instructions are clear and detailed enough even for a beginner sewer to follow along! So if you’ve always wanted to reupholster your existing couch, this is a great DIY to get you started.

For our project, we’ve chosen tools and supplies from Sailrite® to get the job done. We picked Sunbrella Esti Citronelle Upholstery Fabric. This fabric is part of The Sailrite Collection of Sunbrella Upholstery Fabrics. Sunbrella fabrics are known for their incredible fade- and stain-resistant properties. They’re also easy to clean, making them great for homes with kids and pets. We carry hundreds of Sunbrella Upholstery Fabrics in stock and ready to ship right to your door.

To sew our Sunbrella fabric, we’re using the one and only Sailrite® Ultrafeed® LS-1 Sewing Machine. We’ve added the Industrial Sewing Table & Workhorse™ Servo Motor for a permanent sewing station for our project. The Workhorse Servo Motor is a fantastic upgrade to your Ultrafeed machine. Fully adjustable speed settings let you control the top stitching speed so you can sew between 123 and 616 stitches per minute while never losing the ability to sew stitch by stitch as well.

Watch our video and get ready to start your next upholstery project! If you're looking for a complete sofa reupholstery video, check out our full tutorial, “How to Reupholster a Sofa Bed” (300415XHT) where you’ll learn how to completely deconstruct a sofa bed and reupholster it in new fabric. Let us know if you have any questions regarding this project or any questions regarding tools, supplies and products sold at Sailrite. We’re always happy to help our customers tackle their DIYs.

Video Chapters:

  • Cushion Disassembly for Patterning – 0:44 min.
  • Patterning Plate – 1:48 min.
  • Patterning Boxing & Zipper Plaque – 5:04 min.
  • Sewing Tucks at Forward Edge – 11:00 min.
  • Sewing Plate & Boxing Together – 12:15 min.
  • Stuffing Foam in Cushion – 21:42 min.
  • Materials List – 23:12 min.

Materials List:

  • Upholstery Fabric from Sailrite (we chose Sunbrella® Sailrite® Esti Citronelle #44349-0003)
  • V-69 Bonded Nylon Thread
  • YKK® Continuous Zipper Chain #5 White (Coil) #104387
  • YKK® Zipper Slider #5 White Metal Single Lock Pull (Coil) #104356

Tools List:

  • Multi Use Pins 1 1/2" #102985
  • Thread Clipper "Kuroha" #121908
  • Gingher® Scissors Right Hand Lightweight 8" #101017
  • Tape Measure 120 Inch #102986
  • Sailrite® Ultrafeed® LS-1 BASIC Walking Foot Sewing Machine #300501
  • Sailrite® Ultrafeed® Industrial Sewing Table & Workhorse™ Servo Motor #120931