The Making of a Bench Cushion

This bench cushion has a long cut out in the middle.  We first mark the foam and then cut with the foam saw.

 All foam is cut with perfectly flat sides.  It is difficult to get a cover to be tight on a flat surface, so we wrap the foam with either a polyester or a down/feather envelope to help tighten the top and bottom panels of the cover.  For this cushion we are gluing the bonded polyester to the foam.

The polyester is cut to the same shape as the foam.  On this cushion, it sits on the  top and bottom of the foam core only.  We left the edges free of polyester because we want the cover to have a flat front. 

The foam in these photos is 2 1/2" thick and will be covered with a cover that has a finished boxing panel of 2 1/2" too.  The edges of the foam will hold the piping on the cover straight while the polyester will push up against the top and bottom panels, creating a crown and making the cover look tight and fit.