How to Reupholster the Seat for a Pontoon Bench

Item # X-HT-300449

Is the seating on your pontoon boat looking a little worse for wear? Well, you’re in luck, because we’ve got a solution. In this blog, we'll show you how to reupholster a pontoon boat's bench seat. This tutorial will highlight the reupholstering of the seat cushion. It will cover removing the vinyl, replacing the foam, sewing up a new vinyl cover and stapling it in place onto the backer-board. As part of our Pontoon Upholstery Series, we'll be providing numerous videos on how to spruce up your boat seating.

A lot of pontoon boats have bench seats like the one we’ll be revamping in our video. After years of use, those bench seats made with inferior products tend to fail miserably. That’s why we’ll be completely removing the vinyl and foam on our bench seat using only the highest quality products from Sailrite®.

In this tutorial, you have the option of keeping your old foam from the original bench seat if it’s in good condition. But if that isn’t the case, we’ll walk you through the process of cutting new foam and shaping it to match the original bench seat. With so many superior foam products to choose from at Sailrite, it can difficult to know which you should pick. That’s why we’ve created several resources to help you decide — simply reference the “More Helpful How-Tos" section of this blog! You can also order our Foam Sample Box (#121658), which includes all of our various foam products plus a helpful chart so you can determine which foam product will suit your application. To cut our foam we'll be using the dual-blade Sailrite® Blade Foam Saw, which is a must-have tool for anyone working with cumbersome foam. This tool creates clean, even cuts and makes short work of thick foam.

For our vinyl upholstery, we’ve chosen to use the extremely soft, supple EverSoft™ Indoor/Outdoor vinyl. This waterproof fabric has a grain that closely resembles real leather and provides extensive protection against abrasion, fading, mold and mildew. It contours exquisitely around corners without sagging or puddling, so you’ll get a professional-looking application every time.

How did your pontoon seat turn out? Let us know in the comments below.

Video Chapters:

  • Removing Old Vinyl Fabric – 1:03 min.
  • Cutting & Shaping New Foam – 4:33 min.
  • Patterning Four-Way Stretch Vinyl – 20:56 min.
  • Making Piping – 28:01 min.
  • Sewing Front Bolster Vinyl – 33:48 min.
  • Sewing Back Seating Vinyl – 45:15 min.
  • Adding a Fabric Pull – 52:41 min.
  • Joining Panels – 56:27 min.
  • Stapling Fabric Pull – 1:05:51 min.
  • Stapling Vinyl Fabric to Backerboard – 1:09:44 min.
  • Adding Cushion Underlining – 1:18:26 min.
  • Materials List – 1:20:10 min.

Materials List:

  • Medium Density Polyurethane Antimicrobial Foam (Medium) 3" x 24" x 80" - (#183M2480)
  • Medium Density Polyurethane Antimicrobial Foam (Medium) 4" x 24" x 80" - (#184M2480)
  • Foam Lock Spray Adhesive 12oz - (#120464)
  • Dura Skrim® Patterning Material 74"- (#122463)
  • Fabric Backed Sew Foam 58" - ¼” - Item # 121506 or ½” - (#121507)
  • EverSoft™ Indoor/Outdoor Off White 54" Vinyl Fabric - (#122211)
  • Foam Piping/Welting Cord 5/32" (50') - (#105599)
  • Thread V-92 Natural Polyester UV 4oz - (#106386)
  • Sur Last® 60" Fabric - Item # 385100 or Top Notch® 9 60” Fabric - (#120451)
  • 21 Gauge 3/8" (10mm) Staples 10,000/Box (Stainless Steel) - (#8010SS)
  • Cushion Underlining Beige 54" Fabric - (#103934)

Tools List:

  • Tack & Staple Remover - (#104319)
  • Staple Lifter - (#120037)
  • Sailrite® Blade Foam Saw V2 with Carrying Case - (#121244)
  • Tape Measure 120 Inch - (#102986)
  • Clear Acrylic Ruler 6" x 24" - (#102400)
  • Gingher® Scissors Right Hand Lightweight 8" - (#101017)
  • Sailrite® Fabricator® Sewing Machine, Table & Workhorse™ Servo Motor - (#400500)
  • Cording Foot Set 1/4" for Fabricator - (#400414)
  • Sailrite® Short Nose Upholstery Staple Gun - (#121410)
  • Cushion Wrap Silk Film 54" - (#103933)