Expert: Mark H. Miller - 6/13/2007

Question
We recently purchased two used couches and have noticed an unpleasant odor coming from the cushions.  we had the couches sanitized, deodorized and then steam cleaned but the smell is still persistent.  i'm purchasing Pillow Forms 2" bigger than then back and arm cushions, but the bottom cushions are a problem.  currently they are filled with Foam and wrapped in Batting.  Should i remove the foam to measure the cushions like i did for the back and arm pillows?  with the foam inside of the cushion it measures 25.5x23x5.  what are the guidelines for purchasing foam and what are the steps i should take to refill my cushions?  Are certain types of foam better than others?

Answer
Hi,  first of all you do have to replace the fillers, the odor will never come out.

Measure the cushion along the front edge from corner to corner and add nothing to that measurement, be certain to measure inside the welting (piping)

Measure front to back along one edge, again inside the welting and add 1/2 inch to that.

Measure the thickness of the cushion in front, the height from seam to seam and do not include the welting in that measurement,  add 1 inch to the thickness.

Decide on the density of the foam by how you like to sit,  med. firm, firm, extra firm, etc.   Purchase H.R. (high resiliency) foam.  Most likely that will not be the quality foam that is available in yardage shops.    If there isn't a good upholstery supplier in your area contact Foamorder.com they will ship and the quality is excellent.
They will also sell bonded dacron or even better, quilted dacron.  I will tell you about dacron in a minute.

You can also purchase the foam a little larger to be safe and then cut it with an ordinary wood saw or electric carving knife.

You then have to add padding around the foam.  For that use bonded Dacron or bonded polyester.  You may have to put several layers on the top and bottom only to give the cushion a "crown"  or loft.  and then one layer over the whole thing to hold everything in place.  

You can hold the whole thing together with an ordinary hand stapler or a few whip stitches.

When you push the filler into the cushion it should fit snug but not buckle.  Run your hand around the perimiter of the inside filler and push the selvage area of the seams so that they lay flat along the SIDES of the cushion, they will want to lay on top and that doesn't look good.  Push the filler as much as possible toward the front of the cushion for the best look.

I hope this information helps.  Please don't hesitate to contact me if you have further questions.

Good luck.

Mark Miller.