Boat cushions from stock foam

[xluke]

Hello,
Does anyone know a good way to cut down foam to make boat cushions? Maybe a hot wire, but how? Or just a razor? Some sort of saw? Finding foam on the bulk market is pretty cheap but I don't know how I would cut it to size. (of course upholstery would be another hurdle but one step at a time!).

Thanks!

[nightowle]

I've read that an electric carving knife is the best way. believe it or not!

[chef2sail]

Electric carving knife works. You cant really just use any type of bulk foam for interior or exterior cushions.

Choose the wrong kind for your particular area you have major mold and mildew or it retains moisture. Good foam is not cheap either. If you are going to go through the effort of replacing interior cushions, the job is a large one and there is no sense skimping on one of the two major components ( foam and upholstery fabric), Read up on doing this..
dave

[labatt]

Another method is to get a 2x4 with clean/sharp edges and push it down where you want to cut the foam. Then cut the compressed foam along the 2x4 with a utility knife (the better shape the edge of the 2x4 is in, the cleaner the cut). We didn't have a hot knife and this method worked well.

[SlowButSteady]

I'll second C2S's comment getting quality foam. Upholstery foam isn't cheap. It has to be firm enough to keep you from "bottoming out", without being so dense as to retain moisture for too long. The latter property being even more important on a boat. Cheap foam usually sacrifices one of the properties for the other. Also, a good quality cushion often has quite a bit of polyester batting, in addition to the foam. When this batting is missing the cushion will look too flat and feel like a "cheap foam cushion" (for lack of a better descriptor) when you sit or lie down on it.

[genieskip]

Sailrite's website has a number of free videos on the subject of making cushions. They also have a DVD for around twenty bucks that explains everything. Using their info I redid all the cushions on my boat and a number of them on my son's junker.

I used an old electric knife to cut foam and that works the best. The two serrated blades working in opposition give the best cut.

[spec2]

I made my own exterior cushions for my C &C 99 after pricing out a few local and web-based shops. First, find a local Foam company. I found one in Hartford CT. Make cardboard templates of your cushions. Be sure to mark the templates Port/Starboard/Top/Bottom. Bring templates with you to the Foam shop. Explain the application. The foam needs to be dense, but more importantly, it needs to breathe. Have the Foam shop cut the foam for you. They have the correct equipment. Next step is to Jo-Ann Fabrics for Sunbrella. Wait until they have a sale. Check out their Web site. Take your foam there. They have well-trained staff that will measure the correct amount of fabric you need. I added zippers enabling me to clean as needed and straps like those found on a backpack to cover my open-transom seat. Found all the stuff needed at Jo-Ann's. Then you need a seamstress. Since you're already at Jo-Ann's, I suggest you ask the staff if anyone would be interested in completing your project. Craigslist is helpful. Also, you can find seamstress's at stores like Macy's etc... Find one of these nice ole folks in the store and ask 'em if they do work on the side. At the end of the day, I saved about 30% doing this on my own. A bit of running around here, but we're all cheapskates....aren't we?

[Barquito]

I second the method of using an electric knife.

I got my foam from a vendor I found on e-bay. You do need to know what the density numbers mean to get the right stuff.

I found good prices (and cheap samples) for fabric from FabricGuru.com. There are some brands that are a little cheaper than sunbrella (and probably not as good).

[HPLou]

An electric knife will definitely do the job in cutting the foam. Another option would be to use a really sharp fillet knife. I've used both with very good results.

[QuickMick]

lots of good cushion ideas here:

http://www.sailnet.com/forums/gear-m...-smooshin.html

a real slick idea of using beans and foam (loose) for a bean bag effect.