How to Use High Density Foam for Upholstery

Learn all you can about foam. For starters, it's a good idea to buy foam that's fire resistant (FR) and high resilient (HR)--the latter designation means the product will last longer. Then consider the indentation load deflection (ILD), which tells you how firm the foam will be. Firmness is a personal choice, but a lot of people like their back cushions softer than the ones they sit on. Finally, there's density, which is different than firmness. Higher density means a heavier, more expensive foam that holds up better than the lower-density stuff.

Order precut foam--or, if you're handy, cut your own cushions from a solid piece of foam. For the best results, draw a line to guide you, and cut with an electric serrated knife or a circular saw. If you're going work on many foam projects, consider buying a special saw for the job (see Resources). For safety's sake, go slowly with any saw or knife, and keep your fingers out of the way.

Fold Dacron wrap around the foam cushion, and attach it with a foam glue adhesive. This softens the edges so the final cushion looks more professional. This layer has another purpose as well: You'll find it's easier to insert the wrapped foam into the cushion cover.