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Old 08-31-2019, 07:41 AM   #1
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Replaced my factory Foam with Firmer

Well I finally replace my factory seat foam with firmer Lux-HQ foam from Foam Factory www.foambymail.com. Purchased a FULL sheet of their premium LUX -HQ. https://www.foambymail.com/LHQ/lux-h...lity-foam.html
It arrived via FedEx a couple of days later in a vacuum bag rolled inside a box. They recommended open the bag immediately allowing the foam to expand for 24-48 hours to get to full size before working with it. I did this project by myself and it only took 2 1/2 hours start to finish! SUPER EASY project.
Once you remove the “old” foam from their covers:

1. Lay old foam on top and trace, I used a sharpie and tried to use as many of the factory edges as I could to reduce the number of cuts I had to made.

2. Cut out shapes with $9 electric carving knife from Walmart, I cut out the cushions roughly first to make them easier to handle for finish cut.

3. Rap new foam in Dacron and attach with 3M Super 77 spray adhesive. Spray just the. Edges of the foam and Dacron.

4. Reinstall cushion coverer over new foam. Take your time and get everything nice and straight.

There was nothing wrong with the factory foam. It was just to soft for my liking.
Back Pain can make sitting on old cushions not very enjoyable.

If anyone would like the factory foam let me know. I am not going to save it.
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Old 08-31-2019, 12:06 PM   #2
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Nice. Did you do the backs too or just the seat cushions? Did you have to piece two pieces of foam for the odd shaped cushions? I'm trying to figure out where a couple of those odd shapes go, such as the one that you have marked 'top?'
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Old 08-31-2019, 12:15 PM   #3
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I just did the bottom cushions. No I did not have to piece anything together. One full sheet was enough to cut out full cushions.
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Old 08-31-2019, 12:19 PM   #4
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However you do it, it's a project worth doing. We used an upholstery shop that is reasonably priced. But then we only did the sit cushions. Whatever your method or scope, do it. Pat
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Old 08-31-2019, 12:21 PM   #5
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You know what it is...the scale/angle of the photos made the pieces look small to my wacked out eyeballs. The square of original foam is obviously much bigger than it looks in the photo. Might be adding this to the list because....why not?
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Old 08-31-2019, 12:25 PM   #6
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Quote:
Originally Posted by PKI View Post
However you do it, it's a project worth doing. We used an upholstery shop that is reasonably priced. But then we only did the sit cushions. Whatever your method or scope, do it. Pat
Total cost 208.99. Worth every penny.
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Old 08-31-2019, 12:28 PM   #7
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Quote:
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You know what it is...the scale/angle of the photos made the pieces look small to my wacked out eyeballs. The square of original foam is obviously much bigger than it looks in the photo. Might be adding this to the list because....why not?
Yep angles are tough. I had to stand on a ladder to get this in one pic. Foam was 82”x76”. It was huge.
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Old 08-31-2019, 01:04 PM   #8
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Great Job!
What is the Dacron for?
Did you leave the edges uncovered?
What is the "seat of the pants" difference? Firm enough?
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Old 08-31-2019, 01:28 PM   #9
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The dacron interests me too. I am pretty sure it used to be unbleached linen or cotton and it was sewn over the foam. 1/2 of one seam had to be done by hand! Agony. It helps prolong the life and shape of the foam and makes it a tad easier to slip the foam into the cover. Dacron should have even less friction, and glue - fast and brilliant.

Another benefit is that the upholstery does not get skewed around by wiggley children or hefty slouchers. We had one chair that my mother re-upholstered without a liner... I swear ot took half an hour every week to untwist the seat cushions. I bet this will look nice all the time.

Thanks for the inspiration.
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Old 08-31-2019, 01:35 PM   #10
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I think AS is trying to split the difference between firm foam that is nice to sit on and softer foam for if you use the cushions to sleep on. Not sure if that's quite possible since the foam is definitely a bit soft to sit on, but some nights either my wife or I uses the dinette as a bed, and I would not want firmer foam for that.
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Old 08-31-2019, 01:56 PM   #11
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Here is a link to a foam supplier. They have a great resource.
https://www.foambymail.com/do-it-you...-cushions.html
Here is how I did my Dacron
https://www.foambymail.com/GLUEFIBER.html
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Old 08-31-2019, 02:46 PM   #12
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Quote:
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-- snip -- uses the dinette as a bed, and I would not want firmer foam for that.
A topper might be the solution. We alway purchase a firm mattress. However, the last one was a pillow top. All future will be as well. Old muscles and joints need a little cushion. Pat
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Old 08-31-2019, 05:08 PM   #13
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A topper might be the solution. We alway purchase a firm mattress. However, the last one was a pillow top. All future will be as well. Old muscles and joints need a little cushion. Pat
I've been thinking about that, but we don't use it as a bed all the time, and we do use the dinette almost every morning. In the 20' trailer I'm not sure where I'd store it during the day.
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Old 08-31-2019, 09:21 PM   #14
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Bag it and use it for a pillow when not needed for the bed. Or not. Space is always a premium and compromise brings you to how that space is used. Good luck working it out. Pat

Edit - a sleeping bag can somewhat serve the purpose of a topper and compacts quite nicely when not in use. Maybe?
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Old 08-31-2019, 09:50 PM   #15
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Great thread. Thanks
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Old 08-31-2019, 10:53 PM   #16
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Great upgrade
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Old 09-01-2019, 07:51 AM   #17
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Your post got me thinking, and that's always dangerous.
I looked at your foam supplier, the only foam in 5" thickness is the HQ blue you got.
I also agree with those who said it needs to be soft for sleeping.
I wonder the practically of buying two foams; 3" very firm and 2" less firm and making a sandwich of the two. Put the softer side up for sleeping? Or even a firmer foam under your knees and softer under the seat.
My cushions make me feel like I'm leaning forward. I always sit in the same spot, so maybe I've compressed that area?
I see a science experiment in my future.
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Old 09-01-2019, 08:11 AM   #18
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Great write-up, Ronnie... as always
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Old 09-01-2019, 11:23 AM   #19
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-- snip -- My cushions make me feel like I'm leaning forward. .
For those thinking, but not ready to do, try a pair of folded towels along the front edge of the cushion. You can adjust some of the crush out. It also helps to fine tune one seat when the others are just right.

And if a towel is too "shade tree" for you, the kneeling pads that gardeners use can be an alternative.

However, IMHO best to firm up. Pat
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Old 09-01-2019, 12:10 PM   #20
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Dacron FIBERFILL. OK now I get it. That makes cushions look softer and helps cool them down quickly after a person gets up. Low density. This stuff is used in quilting quite regularly. Replaced cotton or wool batting.

Another trick for stuffing the foam into the upholstery (which has to fit like a sausage casing to prevent wrinkles). Use lightweight plastic bag ... drycleaner bag with the hanger hole taped shut or cheap trashcan bags. Put the foam inside with the open end where the zipper is located on the cover. Use a vacuum cleaner hose to suck as much of the air out as you can. While the cushion is a bit collapsed, have a helper put the cover on the foam. Reach in and rip the cheap bag out. Zip the cover. Done.

I started to learn basic sewing when I was 3. (Got caught playing with the machine) A lot has changed and mostly improved. But most of it makes me feel that I need refresher course every 18 months or so. Having an inner layer of muslin is a great idea if you are doing velvet with roll and tuck or tufted furniture. Not so much for plain cushions.
less work is good. Thanks for the fiberfill info. Never knew about gluing it before.
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