Expert: Mark H. Miller - 8/16/2007

Question
QUESTION: Dear Mark;  I have lovely Wim and Karen teak dining room chairs that are about 20 years old and need recovering.  I am in the process of taking off the old material and have discovered that at least one of the plywood seat forms (the thing that the foam, batting and fabric is attached to) is somewhat cracked.  How can I go about replacing or repairing these plywood forms?  They appeared to be somewhat bowed in the middle--it that by design, or is that from use.  also, they have threaded seats for the bolts that hold the chair to the frame sunk into them--if I need to replace them, can you tell me what they are called and where I might find them, ie., what kind of store?  thanks, Barbara in Brooklyn

ANSWER: Hi Barbara,

There is no place to buy precut plywood seats,  you would have to go to a lumber yard and buy plywood, possibly a small skill or circle saw and cut them.  If they have to be moulded, soak them in water overnight, and then clamp them to the chair frame,  as they dry they will remain in the bowed shape.  It is unlikely that they bowed from use.

I don't understand "threaded seats" please restate that question.

Don't hesitate to contact me if you need further clarification,  I hope this helps.  Good for you for upholstering your own seats.

Mark Miller.

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

QUESTION: dear Mark;  thanks for the advice; it turns out that the seats are not all cracked; next question, what kind of foam should I use to pad the seats--I don't want to have to do this project over in a couple of years, and I want these chairs to be VERY comfortable, for long Passover Seders and the like.  I live in NYC, so there is every kind of foam imaginable available and I'm overwhelmed with choices.  Also, the fabric covers that I'm removing are not simply a single piece of cloth, they are made sort of like a hat, to allow for the height of the padding.  Should I attempt to replicate this, i.e, what are the advantages?  Thanks so much for your time.  Barbara in Brooklyn

Answer
Hi Barbara,

I recommend that you purchase HR  (high resilience) foam,  medium firm density.  That quality foam is usually not available in fabric stores,  you may need to go to an upholsterer.  Or you can purchase it from Foamorder.com and they will even cut to size.

The thicker the foam the more comfort,  to determine the maximum amount of foam measure from the top of the seat to the floor,  standard seating height is 18"  19" absolute maximum or people may not reach the floor with their feet.  Foam is usually sold in 1" increments, 2" foam would be ideal.

If you cut the foam yourself best way is using an electric carving knife.  The foam should be about 1/4 " larger than the plywood seat so that you don't feel the wood edges.

The method of upholstering right now has a seam around the perimeter, I recommend that you eliminate that and just pull the material over in one piece.  Place a staple in the center of the front and back, and then in the center on each side.  Then work the fabric towards the corners smoothing it as you go.  You may have to place a few pleats on the corners and if you have the same number on each corner it will look just fine.

I hope you will have fun doing your project.

Mark Miller.