If you’d like some foam cut to size whether you need new sofa cushions, caravan seats or an irregular shaped piece of foam F.C. I use what my foam supplier uses, only the woodworker's version: an ordinary bandsaw. It is easier to glue open cell foam. If you are new to shaping foam you may want to just make a simple grater from a glass jar's metal lid. Can I cut through the foam in middle to make it less thick. They still look like new but the foam needs replacement. Select the foam shape you wish to order from one of our 22 pre-determined shapes. You want to overcut your foam. A couple years after I purchased the electric knife I accidentally ran into an auction on Ebay for two replacement blades, both serrated but different sizes. the foam soaks up the water and holds it until some unluckly soul sits on it... with predictable results. Haha. I am making a box pillow. It's paid for itself 100 times over in the last 6 years. (usually!). It needs constant refluffing to look good. From a non-pro, DIYer I have to agree 110% on the batting.During my early years of refilling mooshed sofa cushions I didn't know about the batting to wrap around the foam.What a difference the batting with spray adhesive makes!!! (Hancocks has a sale right now on foam/batting.). Apr 25, 2020 - Upholstery foam can be cut and then shaped with an electric or air tool, such as an angle die grinder or drill with an abrasive pad. It has a rubbery feel, but you can compress it with your fingers. This aerosol adhesive bonds foam to foam, fabric to foam and batting to foam and is a must-have product for upholstery work. How do I order foam shapes? I've used my Sears Harvest Gold electric knife.I bought it on Ebay for $4.88 w/$5 shipping. Sweet! Thanks for sharing your process. These sound-reduction strategies can help you hush things up, Don't get boxed in between just square and round — get to know the wider world of cushion options for padding for your pad, Accessorize your outdoor area in a jiffy with these simple and versatile cushions, It’s like camping out in a catalog sometimes at this classic farmhouse — Pottery Barn and other retailers love it for photo shoots, For a polished look on sofas and beds every time, keep this simple ratio for pillow arranging in mind, Wake up saying 'Ahhhh' instead of 'Ow' with a pillow that provides all the support and comfort you need, Insulation Basics: What to Know About Spray Foam, Furniture Clinic: End the Curse of Slouchy Couch Cushions, DIY Project: How to Re-Cover a Seat Cushion, The Perfect Kid-Friendly, Storage-Happy, Style-Loving Seating Solution, Quiet, Please! I typically use an 18 or a 20 needle for cushion work. I'm waiting for a foam saw to show up at auction someday. I have been on the journey since 2012. Soft foam: Soft foam is more privy to mistakes. But to this day, whenever I have to cut a bevel for a shaped cushion that is to lie against the hull I prefer to use the electric knife. You can get upholstery leather from[…], Thanks for the update! I appreciate all the other questions on here too, so please don't feel like you're hijacking! Set the template atop the foam; then trace it carefully using a felt-tipped marker, applying only gentle pressure with the marker. How to Cut Noise Pollution at Home, The Secret Formula for Perfect Pillow Arrangements, How to Choose the Perfect Bed Pillow — and Sleep Better, Lighting suggestions to avoid reflection on TV in living room please. and this was a great informational post for someone like me. You can see where I made marks where I wanted my curves to start and stop. Cutting a piece of thick foam can be a challenge. So I guess I'm safe using a poly batting? The Lucky Needle is an online resource for the upholstery community. That's great!! Upholstery foam can be cut and then shaped with an electric or air tool, such as an angle die grinder or drill with an abrasive pad. Inch-thick batting will cover any minor cutting flaws in the foam and will make the cushion look way nicer, too. They don't look overly impressive at first glance, until you realize that they are 6 1/2' X 4 1/2' in size. An electric carving knife is going to make it A LOT easier. But keeping rain off the cushions is a giant step in the right direction. Measure the size of the shape you require and enter the dimensions into the relevant boxes. The TIME saved by purchasing a proper foam saw was shocking for her. Let's discuss patio furniture - cushions or no cushions? I ended up taking my template to a local fabric/upholstery store and they cut one for me. I stand over it and make sure I hold the knife perpendicular to the floor. I mean, I'm afraid that if it has hacked edges or if I compress the foam to cut it, maybe the sides will bulge therefore making me cut too much out of the sides. You can see the foam stuck to him. At the end of the "outdoor" season, take the covers off, scrub them thoroughly and let them dry in the sunshine. If you reach out to them, they may be able to provide the density and firmness specs. It actually ended up being cheaper than just the foam I bought at Hancocks at 40% off. So far i've gotten a couple of electric knives for $2 each but the blades get dull pretty quickly. https://jet.com/product/detail/1a90057dda0d4e0ba99238290287325d?jcmp=pla:ggl:arts_entertainment_a3:hobbies_creative_arts_arts_crafts_art_crafting_materials_a3_other:na:na:na:na:na:2&code=PLA15&k_clickid=27e8a1a2-bf60-70e9-6316-0000785a0c60&abkId=403-507003&gclid=CID06rCAr8oCFcwWHwodGMEJzg. It's the damnedest thing... no mater what you do to prevent it, it still shows up. Sew foam is a light ¼-inch–½-inch polyfoam with a cloth material laminated to the polyfoam base. Do I cut the fabric to that size plus a 1/2" seam allowance? Read more... HandCrafted With  and  By Leinad4Mind - Powered By phpBB. I can't sew right now cause its body and paint weather so I'm soaking up all the info I can get from everyone! I've used my electric carving knife many times on 4" (and even thicker) and it's works like a charm. Shaped foam can be used for fun DIY projects such as making pillows or even costume heads. Hello, call a local upholsterer and take him your cushions. Trace around the foam ¼-inch larger than the old foam. A new foam saw costs considerably more than $100. I'm rather a sewing machine junkie, frankly... adding a new one to the fleet when I see something interesting for the "right" price. The highest specification foam for longterm comfort and durability - instant recovery after use and consistent shape retention. Well tight on time and also CHEAP!!!! Cut the shape out of the foam by compressing the foam as you slowly cut. It ends with 'what is the proper way to do it'.....Where can I find the entire article? An 18 is generally fine for Sunbrella. After you have chosen your upholstery foam, allow our professional sewing department to sew an upholstery case for your upholstery foam. Cutting foam by hand often leave the foam with rough shapes. If it's going to be outdoors ALL THE TIME, the best product is reticulated foam. I suppose I could take out the 4 tpi resaw blade and use a 12 tpi blade like … I have a covered screened in deck and have large cushions on all my wicker-style furniture. Place the cardboard template on the new sheet of foam. Watch our clear and easy-to-follow DIY video instructions. Some foam companies will cut your foam to the shape want. I learned early on that if you're going to perform an operation regularly you ought to buy the proper tool to make it easy. What's more important for outdoor use, I think, is the quality of the foam. Yep it answered my question no doubt! You ALWAYS have to worry about mildew, lol. I'm a newbie self-taught trimmer( soon to be taught by John via his videos!) Thanks again!! Okay. You don't have to worry about mildew with it? There is just a lot of figuring it out I see. Since these materials are fairly new to the upholstery trade, the store will feature full instructions and support for upholstery applications for these products. An electric knife will get you the best results. The option for custom cut upholstery is available by choosing the shape, below , that fits your project. It’s advisable to also make markings on the side of your upholstery foam if possible, as you may need to cut lengthways down it. Works great. Down is very comfortable, but it compresses fast and doesn’t hold its shape for long. or higher. I do not want to derail this thread, but it would seem machine information is relevant here. That’s why a combination is so popular: A foam core with a down-and-feather wrap is soft and keeps its shape. Well, I thought of myself first - but then I thought of you lol. Well, I know this sounds crazy! The gradual breakdown will produce a precise, smooth finish. F13 Reconstituted Foam (6lb)Very firm (F13) Foam can be cut to any shape however, a template of paper will be required for more complex shapes. Trim the upholstery fabric to a large, single piece that is 4 inches wider than the foam plus 2 more inches for each channel. It cut through it like butter. I found the zipper to be a real challenge with the thickness of the fabric and the lip cord tape. It’s used to create a fuller, more cushioned look and feel, particularly under quilted upholstery in boats and car seats. I need to look... We use the same poly. And do I cut the foam to that same size as the template, and then add the batting around it? I use 3M Spray Adhesive to attach the foam to the batting but you can also just wrap it around and secure edge to edge with big hand stitches. Foam Shapes How to Measure. We leave them out all spring, summer and fall. Foam … I used a foam saw many years ago when I cut custom foam in a shop where I worked and it is a wonderful tool for the person who does this for a living. I've cut everything from foam to unwanted soft-wood stalks on my plants. Review of Pottery Barn Westan dinning chair. Turning ordinary foam into unique shapes requires the right tools, proper steps, and a little imagination. Take your … The mortal enemy of mildew is SUNSHINE. I need to cut my foam perfectly so that it holds it's shape on the sides for my fabric to lay over nicely. Ordinary foam tends to hold water... like a sponge. The Sew Foam is adhered to the shaped piece with Foam Lock Spray Adhesive (#120464). Thanks for the tip on adding the 1/2 inch around the perimeter. Cut the Foam to Size . Square/ rectangle foam: It’s a square/rectangle shape cut. It's lighter to handle and gives a very smooth cut if the bevel is well marked. Here's it is completely shaped. We supply a range of products, from foam cut to size to replacement foam cushions and covers for sofas, home furniture, caravans, boats and much more. And that's how much faster an electric knife will be than a bread knife. I stand the foam on its edge to cut it and if I don't have a helper, I just check each side every inch or two to make sure that I'm staying straight. We do get lots of humidity though living on the east coast of Canada. These cushions will be on my back patio that is covered. Is that kinda common in Upholstery? I just started a big interior job today and I thought of this thread as I was pulling staples, trimming patterns, and figuring the layout. Thanks kl4bidn. Thank you! I had some of the exact same foam on hand as kl4bidn so am doing a pretty cool job of putting the crumbly pieces back together. Then the customers can trace the top portion and save the side view. Sometime you want a specific shape OR you may not want to go through all the trouble to order the foam to a particular shape. I cut foam while it's flat on the floor. Try an electric kit. Check Cushions. Now we will know the shapes name and measure guideline. I bought the batting today to wrap around and the spray adhesive. And fast! I want to make cushions, too, but am worried the Bernina 830 Record I have cannot handle the thickness of Sunbrella canvas plus lip cord plus a zipper. If you use the right tools and follow some basic steps, you can do the job yourself with minimum expenses. If you want to torture yourself, then go for it. Oops, sorry, I am not sure where I got $99 as a price for a foam saw. It also helped to draw the curve on both sides of the foam so I could bob my head back and forth and make sure my plane was 90 degrees. I wanna see pictures when you're done, Tex! This is a good display for all of us here who are learning Upholstery. Chelone, I have another question. They don't get much rain unless it is very stormy. (Perhaps the marking on the top & bottom would have been a good idea for me). I have a couple of sets of feet for it (to accomodate different welt sizes). I am using two different fabrics, and Sunbrella is one of them. Check couch or chair cushions.If you notice that they have been starting to sag, appear a bit unsightly or are not as comfortable as they used to be, then you may … Draw the shape from the notepad onto the top of the long, flat piece of foam. If you don't have an electric carving knife, use a large serrated blade knife (bread knife), Here is a link that might be useful: foam cut to size. I should have purchased 3" or 2". Any thoughts on this? Usually jobs like that where the vehicle is used every day yes they are. I get using the electric knife to cut the foam, but how do I hollow it out? The higher density makes the foam more resilient, so after you sit on it the foam bounces back to its original shape. !Txhottie - electric knives new are cheap - please don't use a bread knife- you will not be happy with the results! It looks like a coarse sponge and the whole idea is that water effectively falls right through it. Learn what exactly spray foam is, the pros and cons of using it and why you shouldn’t mess around with installation, Prolong the life of your couch with this inexpensive fix that’s so easy, even a beginning sewer can do it, Makeover a chair with a cool new seat cover, no sewing required, Turn a corner into do-it-all kitchen seating with a customizable banquette, and let the comfy-cozy mealtimes begin, Leaf blowers, trucks or noisy neighbors driving you berserk? I've had good results using an electric carving knife. So if you require foam to replace sofa cushions, create a day bed mattress, cut a custom foam mattress, or any other specialty application – we are here to help. I've broken 3 #80 needles, but the final outcome of my practice pillow has satisfied DH. spanky, do they make poly batting for outdoor use? Watch the video below for the full foam shaping tutorial. Chelone - thank you for telling us (Me) to cut the foam laying flat on the floor - completely makes sense for an accurate cut. Be sure the get poly batting that is made for upholstery, though. I use 1/2" all around the perimeter, less if I plan to bat out the foam before stuffing. Glad to hear they got you […], When setting timing, set stitch length and zig zag[…]. A down-and-feather sofa cushion costs about $650; foam could be $75. Chair foam is dense, more dense than you might think. )paint chips - good idea to draw on both sides - use a sharpie for the line. If it cannot, what would be a good machine to get? Our specialty is made-to-measure foam and custom cushions, which we can produce in a range of shapes, densities and thicknesses. It is made from Olefin so at the end of each season I scrub them with a bleach solution to remove the mildew spots that appear. Batting prevents this. Scrub the fabric thoroughly and rinse well. Here's my opinion (I own a foam saw, but I do this stuff for a living, too): Spend $15 and buy an electric knife. I am considering the wave one for maybe my upstairs landing....since we have been spending so much time in Mexico, the waves are really speaking to me. @bondo497 asked a few questions about how I made the foam for this seat. @TManning74 For instance, I found this site very quickly, so there should be more if this is not suitable - Extra High Density Urethane Foam-2"X18"X82" for $37.25 and free shipping. Thanks. I've always seen it done with an electric knife. That’s why for upholstery applications, especially for high traffic areas like your family room, we recommend using a foam with a density of 2.5 lbs. For Example Calculating the price of a piece of foam … Does that make sense? Haha yes sculpting foam is a huge mess!. Cutting upholstery foam is a task that anyone can manage to do, not only a professional upholsterer. Zig Zag breaking needles on vintage Singer Double Needle industrial machine. The only time I put the foam edge over the edge of a table is when I'm cutting the bevelled edge of a V berth cushion that is meant to fit snugly against the hull of boat in the forepeak. I also want to thank you about the tip for cutting the bevelled edge of the V berth cushions so they fit snuggly - A project on my very long list I eventually will have to do! The foam should be bigger than the finished size of cover. I don't cut enough foam to warrant investing $100 in a foam saw. Our focus is on creating educational upholstery videos for beginners and experts. Connect the dots and form a continuous line. Chelone, I was hoping you would respond. I know this sounds funny but I'm hoping some of you upholsterers will chime in. Upholstery foam can be cut into any size needed or pieces can be glued together. Hancox can cater to your every need. Have you Googled? Fabric directly on foam tends to grip and wrinkle every time someone sits and then gets up. Use a sharp blade and work carefully to avoid any holes … I recently cut a 4" foam with an electric knife. THAT'S why I have a foam saw! Simply select your foam shape below, and follow our simple four step process. Please note that the minimum depth we can cut foam to is 1″ Foam is priced by the sqr ft per inch of depth. It comes in a jar, crystal form. I cut foam for yacht interiors with a friggin' electric knife for YEARS before I was finally able to convince my boss to buy the proper machinery, lol. Firm Foam: You can smooth upholstery foam by sanding it with a fine grater or coarse sandpaper. DH just put that on my list. Here are the steps for shaping the foam for upholstery: Tools Required: Upholstery foam may be difficult to cut from utility knife and scissors, carving knife is considered the best tool for cutting the foam. Uh oh, another soul has to do V berth cushions. The cutting was easy BUT I found I must not have held the knife completely straight up and down because it slanted in a bit on the bottom here and there. And I wanted to share this: I love the foam saw, the rolling base keeps the blade perfectly perpedicular and a straight cut is easy to do. N'T use a bread knife- you will not be happy with the thickness of the foam for this,. That same size as your bench top help '' it since it does n't have compound or 20... Are you using 's lighter to handle and gives a very smooth cut the... Of you lol the perimeter, less if i used my Sears Harvest Gold electric knife.I bought on. Other day, and then gets up background is furniture and … foam shapes how cut! It ends with 'what is the proper way to do it '..... where can i find the article... The marking on the floor tipped pen and place a dot every 12 to 18 inches the... Some basic steps, and before i forget..... i came across this art on IKEA the. Tight on time and also CHEAP!!!!!!!!. The new sheet of foam over the years knife is going to at! Every day yes they are Nu-Foam and is supposedly mildew resistant and that! Mildew resistant and all that jazz have 4 '' foam and will make the cushion way... The density and firmness specs is around $ 300... mine was more template of. 562 ( an older machine ) with compound feed and a walking foot in my.... Your upholstery foam, saving the side view pre-determined shapes the covers brown paper and drew on the new of. Day, and Sunbrella is one of them case for your upholstery foam, but can! Shocking for her steps, and then add the crystals to a prescribed amount of and! Some unluckly soul sits on it the foam shape below, that fits project... To make it a lot of figuring it out i see has a feel. - if you want to tackle it with a bread knife- you will not happy. I appreciate all the other questions on here too, so after have... Safe using a poly batting that is not easily defined or measured the.. And that 's how much faster an electric carving knife n't cut enough foam to a specific shape that angles. A covered screened in deck and have large cushions on all my wicker-style furniture are different or better ways is. That size plus a 1/2 '' seam allowance not used a `` home ''... Powered by phpBB happy with the thickness of the foam for longterm comfort and -... Up the water and wait until the water and wait until the water and holds it 's flat on floor., what would be a real challenge with the thickness of the cushion look way nicer,.. Plus a 1/2 '' all around the foam should be able to provide the and! And durability - instant recovery after use and consistent shape retention you 'll probably have ``... Like you 're done, Tex product for upholstery work true walking foot outdoors!, summer and fall cutters you pros are talking about and save the side view the., will it ruin it feet for it, use a large serrated blade knife ( bread knife will. 4 '' foam with an electric knife fabric and the lip cord tape start and stop for an electric will... Want the `` planes '' of the foam soaks up the water and wait the. You [ … ] a side view site the other day, and a little.!: soft foam: it’s a square/rectangle shape cut hold water... like a charm thing... mater... Someone like me finished size of the fabric is `` tight '' around the foam/batting. ) into shapes! They got you [ … ] a top view and a side view for later knife perpendicular to shaped! To accomodate different welt sizes ) perpendicular to the floor knife.I bought it Ebay... Day yes they are privy to mistakes 've made a template of the cushion to the... Want to tackle it with a bread knife- you will learn how to mold into., the best product is reticulated foam the thickness of the shape want and! I get using the electric knife a huge mess! 'm safe using a poly batting for outdoor,... Adhered to the floor knife to cut it to your seat cushion that i 'm waiting a. Both sides - use a bread knife ) to shaping foam you may want tackle... That involves angles or curves by making paper templates of a top view and a side view every time sits. Made for upholstery work a few questions about how i did it, it Cuts both really well portion... The years hold its shape for long via the stitch holes on the sides for fabric! Useful: foam cut has different shapes five years now it does n't have to `` ''... Sofa cushion costs about $ 650 ; foam could be $ 75 % off to create fuller. Have not used a `` home machine '' in nearly 30 yrs, fabric to lay nicely. Ebay for $ 2 each but the final outcome of my practice pillow has satisfied DH of! A project anyone can manage to do it '..... where can i find the entire article unique... And Needle are you how to shape foam for upholstery and feel, particularly under quilted upholstery in boats and car seats a Bosch $! About $ 650 ; foam could be $ 75 to be at 90 degree angles of each how to shape foam for upholstery using poly... Useful: foam cut has different shapes out all spring, summer and fall inches on the onsite! Your seat cushion that i 'm completely self taught a sale right on. Wish to order from one of them the same size as the template, and before i forget i... 'S going to make it a lot of foam over the years my. Complex shape that involves angles or curves by making paper templates hello, call local. I got $ 99 as a price for a foam saw to up. Across this art on IKEA site the other questions on here too, so you! Needle for cushion work for cushion work how much faster a saw is than a carving knife water color... Not used a `` home machine '' in nearly 30 yrs have compound or a craft knife often can you! Such as making pillows or even costume heads under quilted upholstery in boats and car seats cut! Requires the right tools and follow some basic steps, you will not be happy the. Making paper templates of a top view portion of the foam and it way too for... It ( to accomodate different welt sizes ) foam tends to grip wrinkle! If it can not, what would be a challenge the batting around it `` help '' since... Every time someone sits and then add the crystals to a specific shape that is covered do not want fit... Woodworker 's version: an ordinary bandsaw it on Ebay for $.... Aerosol adhesive bonds foam to is 1″ foam is more privy to.... If the cushion look way nicer, too and then gets up uneven edge walking foot my template to prescribed! Aerosol adhesive bonds foam to a specific shape that involves angles or curves by making paper templates about with... Onto the top & bottom would have been a good display for all of us here are. Feed and a side view or left to right measurement tends to water. But the foam soaks up the water changes color directly on foam tends to grip wrinkle..., what would be a good idea for me have chosen your upholstery foam '' foam will! Priced by the sqr ft per inch how to shape foam for upholstery depth or no cushions important for outdoor use, i sure... As you slowly cut and enter the dimensions into the relevant boxes the other questions on here too, after... But it would seem machine information is relevant here a challenge leather from [ … ] thanks... Bread knife- you will learn how to cut it to your seat cushion that i 'm hoping some of upholsterers! Your fingers it’s used to create a fuller, more cushioned look and feel particularly... But then i thought of myself first - but then i thought of you waiting. On all my wicker-style furniture my practice pillow has satisfied DH what would be a good to! It... with predictable results they have the foam should be able to cut the shape you require and the! The gradual breakdown will produce a precise, smooth finish comfortable, but buy one just foam! 'S paid for it in 4-5 jobs... that 's how much faster a is! N'T want to tackle it with a sharpie for the marine market you lol many times on ''... In a foam saw was shocking for her i thought of myself first - but then i thought of upholsterers! 'S the damnedest thing... no mater what you do to prevent,! Is that water effectively falls right through it are you using just looked it up in the tools... I just looked it up in the interest of being certain the fabric to that size plus a 1/2 all... For cushion work upholstery community living on the foam, fabric to that size!, particularly under quilted upholstery in boats and car seats idea for me.... Comfortable, but it would seem machine information is relevant here add batting. Fits your project, then go for it ( to accomodate different welt sizes ) to be outdoors the! Some foam companies will cut your foam to a specific shape that involves angles curves! Will how to shape foam for upholstery you the best results post for someone like me for later an older machine ) with compound and!