Upholstery 101: How to Reupholster a Chair Like a Pro

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Welcome to our two-part upholstery series! In this comprehensive upholstery tutorial, we’ll show you how to deconstruct an old armchair in desperate need of a DIY overhaul. In Part 1, we remove the old fabric and foam to reveal the frame and inner construction. Follow along with us as we carefully remove the fabric and foam. But don’t throw the old fabric away! We’ll use the existing panels as templates for our new upholstery fabric. Watch Part 1 to see how to take apart a chair, then scroll down for Part 2 where we reupholster the chair with our new materials. Let’s get to work!
Tools List:

Part 1:

  • Sailrite® Scratch Awl #123270
  • Tack & Staple Remover #104319
  • Staple Lifter #120037

Part 2:

  • Sailrite® Blade Foam Saw V2 with Carrying Case (110V) #121244
  • Sailrite® Short Nose Upholstery Staple Gun #121410
  • Sailrite® Long Nose Upholstery Staple Gun #121411
  • Sailrite® Edge Cordless Hotknife 18V Package #122177
  • Small Fabric/Leather Clips (50 pack) #123121
  • Chalk Pencil Cartridge Set #121669
  • Sailrite® Clear Acrylic Ruler 6" x 24" #102400
  • Gingher® 8" Scissors Right Handed #19104
  • Sailrite® Folding Utility Knife With Belt Latch #126525
  • Deluxe 5-1/2" Magnetic Sewing Guide #103597
  • Cording Foot Set for Sailrite® Ultrafeed® LSZ (For Larger Welting) #104854
  • Sailrite® Ultrafeed® LSZ Walking Foot Sewing Machine (110V) #311602
Materials List:

Part 2:

  • Outdura® Rumor Midnight 54" Upholstery Fabric (6672) #124489
  • Upholstery Decking Tan 67" Fabric #123529
  • CushionRite® Premium Foam (Extra Soft) #124320
  • CushionRite® Premium Foam (Soft) #124230
  • CushionRite® Foam & Fabric Spray Adhesive 16.9 oz. #125476
  • Cushion Wrap Silk Film 54" #103933
  • Polyester Batting 55" #124305
  • Clear Grip Adhesive Sheet for Templates & Rulers 12-1/2" x 36" #123104
  • 21 Gauge 1/4" (6mm) Staples 10,000/Box (Galvanized) #8006GZ
  • Foam Piping/Welting Cord 5/32" #122259
  • Upholstery Tack Strips 27" (10 pack) #106422-10

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Part 1: Breakdown

In the first video, we remove the fabric and foam, and take the arms off our chair to make the reupholstery process easier. You’ll only need a few tools for this part of the project — a staple lifter, tack and staple remover, and some basic hand tools. As you take the chair apart, it’s a good idea to take reference photos. This will make the reassembly process much easier and ensure you put the pieces back together in the proper order.

Part 2: Assembly

Now to the fun part — sewing and assembly! First, let’s talk about the fabric and foam we chose for our chair reupholstery. We wanted a durable, abrasion-resistant fabric that can stand up to daily use. We also wanted something easy to clean and maintain. That’s why we chose Outdura® upholstery fabric. This indoor/outdoor performance fabric boasts incredible stain, water, fade and abrasion resistance. With hundreds of patterns and colors to choose from on the Sailrite website, you’re sure to find an Outdura fabric that meets your style and performance standards.

Now, on to foam. Our armchair will sit in a high-traffic area and will be sat on daily. This means we need a high-density polyurethane foam. High-density foam lasts much longer (up to 12 years) than lower-density foams. It also has great compression recovery, which means it bounces back and won’t lose it’s shape after being sat on repeatedly over time. That’s why we chose CushionRite® Premium Foam for our armchair.

Watch our Part 2 video below as our armchair comes together beautifully. 

We hope you enjoyed this comprehensive upholstery tutorial. Have you upholstered an armchair? How did it go? Did you learn any useful sewing tips or DIY techniques? Share them with your fellow DIYers in the comments section below!

And if you’re looking for more project inspiration, we have you covered! Click here to explore our vast library of free how-to videos. We have tutorials for your marine, home, patio, automotive and hobby DIYs. Whatever you’re into, Sailrite has the best sewing supplies and educational resources you’ll find anywhere. Let’s make something great together.

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