Expert: Mark H. Miller - 6/8/2010

Question
QUESTION: Hi- just finished taking apart cushion- pulled off 5 layers of fabric and what looked like cotton filler on top of the springs.  About 5" thick with a layer of burlap (?) between the batting and springs.  What do you recommend I use to redo this cushion?  Cushion goes to a wonderful old whicker rocking chair!  Thanks!  Lisa

ANSWER: Hi,

After removing 5 layers of fabric you have the remnants of what once was a spring cushion.  The spring cushion is long past it's life expectancy.  It is still possible to make a spring cushion, however, you would need an upholsterer skilled in old methods to do that for you.  Spring cushions are very difficult to insert into the cover - a machine called a cushion machine is required to do that,  very few upholsterers have those large and bulky machines any longer - for a layman to make a new spring cushion, is in my opinion not possible.

So my recommendation is that you replace the cushion with a high quality foam and Dacron cushion - poly Dacron cushion,  it won't be the same as an old spring cushion, unfortunately, those have become obsolete.  Or a poly-down cushion, which is a foam core wrapped with a blanket of down,  a poly-down cushion will be closer in comfort to your original spring cushion.

I hope this helps,  please don't hesitate to contact me if you need further information.

Mark Miller

---------- FOLLOW-UP ----------

QUESTION: Hi Mark- thanks for such a speedy reply!! I was thinking that I could attempt to pad the chair, similiar to what was, and make a cover that would fit over the seat- sewing the bottom piece on by hand.  I am somewhat clever with a sewing machine- although I do understand what you are saying- the springs are in pretty good condition= do you still think I should just go with a high quality foam cushion- in the end I might just do that, but with the springs so good- I hate to toss them??  IF I do keep the springs/frame- is it necessary to pad in between the coils of the springs?  AND- would you suggest I use a high quality poly-resin batting to use for the filler?  Thanks again!! Lisa

ANSWER: Hello Lisa,

When you say cushion,  I interpret that to mean a loose cushion that comes off the chair and can be turned over.  If that is not the case and are you talking about a coil spring seat with padding over it?  If your chair does not have a loose cushion but rather coil springs with cushioning (padding) over it - called a tight seat in the trade - like a car seat,  then the answer I gave you in my first response would not apply.  If indeed you do not have a loose cushion then you should replace the padding material that you removed,  add additional padding material - preferable cotton batting or a high quality poly.  What has me confused is why would you want to sew that....    If you have coil springs you should not have to pad between the coils of the springs,  unless you think the coils may rub against each other which would cause a clicking noise as you sit on the chair - to prevent noise coil springs are sometimes wrapped with padding material.  

I hope this makes sense,  if you have further questions I will be better able to answer you if I had a picture of the chair.

I hope this information helps - if you have further questions please don't hesitate to contact me - however, I do need to know if there is a loose cushion or if your chair has a tight seat.

Mark Miller.   

---------- FOLLOW-UP ----------

QUESTION: Hi again- sorry for the confusion.  Yes, the seat comes off- the frame that the coils sit in is one piece.  Right now it is just a frame(metal) with the coils.  I guess I asked about padding between the coils because some of the padding had pushed it's way into some of the coils. (Most likely due to age and use) But, the coils are quiet, so I don't think I will have to pad those.  It basically is a whicker rocker with a loose seat!  Again, just wondering what my best route is in padding it?  Thanks.
Lisa

Answer
Hello Lisa,

What you have is a drop-in seat unit.  You are correct in that the old padding has fallen between the springs and is are not there to silence the springs.

It probably would have been fine to just have left the old filling and all the covers in place.  If you have removed them and need to start all over that's fine too,  first place a heavy burlap over the coil springs - that will keep the new material on top of the springs.  

Once you have the burlap covering the springs put the unit back in the chair,  measure how high it is to the top of the springs.  When you are finished upholstering the height should be no more than 18 inches from the floor - that is maximum seating height.  

From the top of the springs to reach 18 inches will tell you how much foam you should get leave one inch for padding and the upholstery material that will sit on top of the foam,  make certain the total height does not exceed 18 inches.  Most likely you will need 3 or 4 inches of foam.  Do not buy your foam from a fabric store, those foams are often not very good quality and will not hold up over the years.  I recommend Foamorder.com because they will ship anywhere in the U.S. and their quality is very good.  Tell them that you need medium firm foam for seating,  the thinner the foam the firmer it should be - otherwise you will feel the springs - so for 1 or 2 inch thick foam extra firm,  3 to 4 inch foam medium firm.

Purchase H.R. foam (High Resiliency) - over the foam place layers of Dacron batting to get a nice crown and not have the flat surface that just foam will have.  Then to enclose the foam and Dacron put the whole seat up in a muslin cover.  Then over the muslin cover only one layer of Dacron batting and then your upholstery fabric.  

If you follow those steps you will have an excellent seat that should last for 20+ years.  If the upholstery fabric wears out all you would have to do is remove the fabric, remove the Dacron that is on top of the muslin, then add a fresh layer of Dacron and re-upholster.

Don't worry about the cotton batting that was there,  this will be much better.

I hope this helps.  Good luck and have fun doing the job and then sit down and relax.

Mark Miller.