How to Make Weather-Resistant Outdoor Cushions

Outdoor cushions add a lot to your comfort when you are relaxing on the patio or by the pool. The problem, of course, is that they are exposed to sun, wind, rain and even occasionally hail and snow, all of which take a toll. When you see your outdoor cushions need to be replaced, your least expensive option is to make new ones yourself. The project is not difficult and the cushions will look good for at least a season if you use the right materials. For fabric, you need a material that is weather-resistant, such as canvas, acrylic-coated polyester or a polyester-cotton blend. For foam use EZ-Dry weather-resistant polyester foam or something comparable.

Tape measure
Two-inch thick high-density weather-resistant foam
Weather-resistant decorator fabric
Scissors
Straight edge
Fabric marker
Straight pins
Sewing machine
Thread
Needle

Instructions

- 1
  Measure the seat of the chair or lounger. Buy a piece of two-inch-thick high-density foam that will fill those dimensions. Upholstery supply stores and sewing supply stores will usually cut the foam to size for you.
- 2
  Measure two pieces of the weather-resistant fabric that are 1 1/4 inches wider and 1 1/4 inches longer than those dimensions. Cut the fabric at your measurements, providing you with the top and bottom coverings of one cushion. The extra 1 1/4 inches is the seam allowance -- the distance between the edge of the fabric and the seam -- when you sew the cushion covers together. For this project, all seam allowances are 5/8 inch.
- 3
  Measure around the perimeter of the foam. Measure and cut one piece of fabric that is 1 1/4 inches longer and 3 1/4 inches wider. This piece of fabric will form the sides of the cushion, which is referred to as the gusset.
- 4
  Measure and mark a line 5/8 inch in from each side of the pieces of fabric for the top and bottom of the cushion cover. Use a straightedge to make sure the lines are true and mark the fabric on the wrong side with a fabric marker. (The "wrong" side of the fabric is the side you will not see once the cushion is finished. The "right" side of the fabric is the side you will see.) Measure and mark a line 5/8 inch in from each side of the gusset in the same way.
- 5
  Pin the two ends of the gusset together with the right sides of the fabric facing each other. Use straight pins placed perpendicular to the edge of the fabric and two inches apart. Using the sewing machine make a seam along the line you drew to join the ends of the gusset.
- 6
  Pin the gusset to the fabric for the top of the cushion cover (this can be either of the two remaining pieces of fabric in the same way, with the edges of the pieces of fabric aligned and the pins placed three inches to four inches apart). Sew all around the perimeter of the cushion cover top to join it to the gusset. Repeat to attach the bottom of the cushion cover to the gusset, but this time leave a 20-inch gap along one side of the cover. Turn the cover right side out. Stuff the foam into the cushion cover and sew the gap closed using a needle and thread.

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