How to Make a Curved Knee-Roll Cushion

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Curved knee-roll cushions are a popular type of cushion seen in boats. If your boat has this type of cushion and you thought the design was too complicated to replicate — you’re in luck! Sailrite® Project Guy Eric walks through this slightly complex cushion design with step-by-step instructions. Even if this is your first cushion cover project, you’ll be able to follow along with our video tutorial and make your own knee-roll cushion.
Video Chapters:
  • Cutting High & Low Foam Inserts — 1:15
  • Creating Bottom Plate — 5:59 min.
  • Creating Top Plate for Low Foam — 10:59 min.
  • Cutting Top Plate for High Foam — 15:08 min.
  • Creating Match-Up Marks for Plates — 18:42 min.
  • Sewing High & Low Plates Together — 21:36 min.
  • Fashioning Zippered Fabric Pull — 29:37 min.
  • Sewing Fabric Pull on Plate Assembly — 32:55 min.
  • Calculating & Cutting Boxing — 38:25 min.
  • Sewing Boxing to Top Plate Assembly — 47:58 min.
  • Topstitching — 1:09:12 min.
  • Sewing Bottom Plate onto Assembly — 1:19:24 min.
  • Inserting Foam — 1:24:44 min.
Materials List:
  • CushionRite® Premium Antimicrobial Foam (Firm) — #124236
  • CushionRite® Flotation Antimicrobial Foam 1/2” (Extra Firm) — #124250
  • CushionRite® Foam & Fabric Spray Adhesive 16.9 oz. — #125476
  • CushionRite® Premium Foam (Medium) — #124234
  • McLube™ Sailkote 8 oz. — #120679
  • Cushion Underlining White 54" Fabric — #768100
  • Lenzip® #5 White Continuous Coil Zipper Chain — #124597
  • Seamstick 1/4" Basting Tape for Canvas & Upholstery (36 yds.) — #122065
  • Lenzip® #5 White Single N/L Delrin® Zipper Pull (Coil Chain) — #125127
  • Tex 90 Polyester Thread
  • EverSoft™ Pebble Indoor/Outdoor Tan and Off White 54" Vinyl Fabric — #122212 and 122211
  • Fabric Backed Sew Foam 1/4" — #124306
  • Lenzip® #10 White Continuous Coil Zipper Chain — #124599
  • Lenzip® #10 White Single N/L Delrin® Zipper Pull (Coil Chain) — #125129
  • Polyester Fiberfill 15 Denier - Hollow Slick Conjugate — #104467
  • Cushion Wrap Silk Film 54" — #103933
Tools List:
  • Sailrite® Blade Foam Saw V2 with Carrying Case (110V) — #121244
  • 1" Foam Hole Cutter — #123693
  • Scribe-All® Black Marking Pencil for Vinyl — #121977
  • Sailrite® Deluxe Fabricator® Sewing Machine Package (110V) — #400600
  • Seam Ripper Deluxe — #18104
  • Gingher® Scissors Right Hand Lightweight 8" — #101017
  • Sewing Gauge Ruler 6" — #102995
  • Sailrite® Clear Acrylic Ruler 6" x 24" — #102400
  • Fabric Edge Pattern Notching Tool — #124326
  • Deluxe Tape Measure 120" — #123120
  • Basic Thread Snips — #123222
  • Sailrite® Fabric Edge Match Pliers — #123498
  • Suisei Magnetic Sewing Guide — #102983
  • Left Edge Guide Foot Set 3mm for Sailrite® Fabricator® — #125123
  • Sailrite® Battery Operated Thread Burner — #122432
  • Multiuse Pins 1-1/2" (250 pack) — #102985
  • Marker, Drill, Tape Measure, Heat Gun, Shop-Vac

Our knee-roll cushion has a fabric bottom, not a backer board. The cushion is made from two pieces of foam, one piece higher than the other. The higher layer forms the outer curve of the cushion and is what your knees will rest against, giving the edge of the cushion a pleasing, rolled look and providing comfort and support while on your boat.

In this curved knee-roll cushion tutorial you will learn how to:

  • Cut curvy high and low foam pieces for a perfect fit.
  • Add a closed cell foam bottom to keep a cushion from soaking water in through the bottom.
  • Use match-up marks to sew shapely fabric panels together for a great fit.
  • Make and sew in a “Zippered Fabric Pull.”
  • Sew odd-shaped boxing properly to a cushion's top plate.
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We hope you found today’s cushion tutorial inspiring and educational! If you’re updating your boat’s upholstery, we have many more how-to videos and blogs for you to explore. You might be interested in our Pontoon Upholstery Series or our Speedboat Makeover Series.

We’re always looking for new project ideas too! So if you have a project you’d like to see us make, comment below. And if you make a curved knee-roll cushion, be sure to share photos with us. You can post your photos below or tag #Sailrite on social media so we can see all the incredible projects our customers make.

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