Advice on making cockpit cushions

[Saluki86]

I can't believe I am considering this but I may elect to sew my own cockpit cushions for my 1980 C-16.  What makes this so daunting is 1) I have never sewn ANYTHING ever before and 2) I am not a rocket scientist by any means.  My only qualification really is that I have no fear!  Ha.  And my wife thinks I am crazy. 

So I am looking for advice (or for someone to talk me out of it).  So far:

•   I have found this sailrite sewing machine but it is a little pricey (https://www.sailrite.com/Sailrite-Ultrafeed-LS-1-BASIC-Walking-Foot-Sewing-Machine).  Could I use something like this: https://www.ebay.com/p/99003393?iid=163212079473.  I only want to do straight stitching and not zig zag or use the machine for any sail repair.  What features do I need to look for in a machine for this job?
•   I have only found a few videos.  Can anyone recommend any?
•   I have found the sunbrella fabric (https://www.sunbrella.com/).  Are there less expensive alternatives?
•   All the videos I have seen use a zipper in the cushions.  Could I use snaps or velco and would they be easier to sew in?
•   I was thinking of using 2" closed foam.  Never worked with that before either.  Other alternatives/advise?
•   Hutchins will sell me the patterns for $30 and sell me a set of cushions new for $650.

All advise welcome.
Thanks,
Sal

[PalmettoSailor]

Whew!!! Makes me tired just thinking about it. lol Good luck.
Seriously, I'd consider buying the plans and getting an upholsterer do the job, or buy from Hutchins. You didn't quote the price of the machine, then the fabric cost, any repair that must be done to the machine, and all for a one time job???
I'm not a project guy, as you can tell. Just my thoughts.
Favorable winds!

[Ken J]

Here?s an idea that I know someone did - he purchased two foam camping mats at Walmart glued them together - then glued some leftover sunbrella fabric he had to the mats - worked great and not expensive - I have yet to try it - but thinking of doing it

[brackish]

I did a number of sewing projects having never done sewing in the past.  Youtube will be your friend on this one. Your search should be for basic use of a sewing machine.  And once you have the machine you will come up with other things to make or repair for the boat or just in general.  I made cockpit rail cushion tubes and several component covers out of sunbrella, then made a set of fitted sheets for the v-berth.  Currently getting ready to replace the velcro on my mainsail cover and make custom covers for all the exposed wood.

If you are not planning to do sail repair or heavy canvas work, you do not need to spend the money for the sailrite machine.  I bought a cheap, heavy duty machine and it handled the Sunbrella fine.

You can use something other than Sunbrella if you are not planning to leave them in the cockpit full time.  If you are, it is the only material with longevity in my opinion. 

I buy my Sunbrella and all other sewing notions from Sailmakers Supply, Gautier, MS.  My mother lives three miles from their place so I usually buy in person rather than online.  Nice folks.
https://www.sailmakerssupply.com/
remember to buy thread of the type that is UV resistant, they sell it. 

I'm not sure patterns are actually necessary for cushions, might be a measure and make your own type of thing, that is what I did for my fitted sheets.

Closed cell foam fine in my opinion. 

I have a set of cockpit cushions for my 23 that I never use.  Why? My boat stays in the water all the time and they are hard to store, have to stuff them in the cabin when not in use.  They are in one piece each side, consequently you have to raise the whole cushion to get into the cockpit lockers. If you leave them out in the weather the cockpit seat fiberglass will eventually stain and it is hard to get off. I now use a set of those Sportaseats.  Mine are knockoffs but these are the best.  Find them to be a better alternative to cushions more versatile easier to move around and store aboard.
https://www.sportaseat.com/

[deisher6]

Hey Saluki86:
Just recently purchased a $2000, 8 piece set of leather lookin' cushions for the settee in the cabin.  The material was over $650, the craftsmanship was superb.  Anyhow the upholster gave me a Consew 101 sewing machine complete with table, bobbin winder and ect.  The machine is a marvel of engineering from the 1950ish era.  A copy of a manual was available online.  After spending around 70 hours messing around, $60 in material and supplies, I produced an adequate dingy cover, repaired some boat canvas, and produced a 2 X 2.5 X .33 foot cushion for the chart table.  Although very functional the cushion looked as if it had been made by an advanced freshman Home Ec sewing student.

Some thoughts:
-If I were starting over I would purchase a Pfaff walking foot sewing machine for my wife then use it for canvas work when she wasn't looking.
-I recommend using zippers that come apart like on a jacket.  I think that they are easier to sew in two pieces..
-I used the old cushion as a pattern.  You need some type of registration marks to keep the top square with the bottom. and
-I recommend that you use glue to hold seams and hems together.  I also used finger pressing and paper clamps to organize the line up of the material going into the presser foot.  When sewing thick stuff the bottom layer tends to feed faster than the top (the advantage of a walking foot machine) causing puckering.  Again some sort of registration marks are necessary.
-There are several books available on sewing boat stuff.  I have found and passed on at least two free ones from places that swap books.
-This particular Consew 101 is a very tough commercial machine.  It has come drawbacks:  It sewed very fast. I replaced the pulley on the motor with a much smaller one from a table saw.  That helped considerably.  The max stitch length is just about right for sewing cushions.  You don't want to use two short of a stitch.  It is much like providing perforations to tear out the work.
-It was interesting.
-Lastly I may be looking for a free home for the machine.

Hopefully there is an attached picture.

[philb Junkie19]

Gotta second that on the sportaseat. It's fine down flat but is especially comfortable using the back rest.
You might check thrift stores. I found a very old heavy Kenmore machine for 20 bucks that sewed through 2 layers of seat belt webbing and odyssey III fabric.

[CaptK]

I've done a *ton* of sewing. This machine on eBay is a much better machine for what you are planning:
https://www.ebay.com/itm/Rex-607-leather-Portable-Upholstery-Walkingfoot-heavy-duty-Sewing-Machine/323669978926?hash=item4b5c3bef2e:g:6ecAAOxyzGlQ9MZT
Among many others, I have owned a Sailrite LSZ-1, and also this Rex machine, and the Rex is as competent a machine as the ones which Sailrite sells. Also, the accessories are a straight swap. I suspect the Rex is made in the same facility - 'borrowing' in the industry there seems endemic. It does not have the quite the polished finish that the Sailrite machine does, nor the support - and that is a thing which is hard to put a value on, and the folks at Sailrite are unparalleled in this. When I bought my Rex ~3 years ago, it was just over 1/2 what they are selling them for now, so I suspect that sales are good.

That said - if you have room for an industrial table machine like deisher had, and have lots of work to do - they are the bomb. I miss mine. (If deishers needs a home, I might have to adopt. ) What philb points out is also relevant - look for an older machine, called "vintage" usually - 70's or older, even back to a 1920's Singer - and/or one made for use in schools. Ton's of them on eBay. Because of their age and/or intended use/users, the older machines were made simple and robust, the Singer school versions for Home-Ec classes (yes, there used to be those...) were produced by the companies industrial division and made with better/stronger "guts". You'll know by looking underneath/inside - you want a machine that doesn't have lots of bells and whistles (who needs 180 different types of stitches anyway?), and does have metal gears. These will not wear out or break under strain from sewing thick material. Get the biggest motor you can. Don't be in a rush, take your time for research, there are always new great deals - so know what you are getting, first.

Sunbrella is a trade name for a specific type of fabric, "solution dyed acrylic". It is great stuff and was patented, which was why they had a corner on the market for so long and there were no cheaper alternatives. Just like the Fein brand of oscillating tools, or Viagra , once the patent expired a number of other companies began producing basically the same product with a cheaper cost for end users. These do not have the reputation (nor proven history) of Sunbrella, but I wouldn't expect much less of them. Hit Google with "solution dyed acrylic fabric" and you'll find names which you can in turn research.

Also search for discount outdoor fabrics - I used to get great deals from a company based in like Minnesota or S Dakota; someplace cold and way up north which I thought unlikely, but they had great stuff. Last, watch eBay - I used to find very affordable (cheap!!!) end rolls of GoreTex and Sunbrella on there from time to time.

Thread - the old standard was V69 or V92 polyester, which is not expensive and lasts about 1/3 the lifespan of the Sunbrella it was holding together.
Now there is a thread named "Tenara", it is 'Gore Tex thread', and priced as if woven only from the finest hair from the head of the Golden King himself...
BUT - it is worth it, IMO. Sew once, be done with it. Tenara has a lifetime warranty, and is supposedly impervious to UV.

Sewing machine usage is both somewhat of an art, and an arcane knowledge. Learning to 'tune' a machine is a very useful skill that when done properly will make your stitching even and strong, but can be a frustrating task. But I've found them to be one of the most useful tools I've ever owned.

[AirborneJarhead]

Well, I sure wish I would have seen this thread earlier. Here's my 2 cents...
I own my own boat canvas biz (that I currently have on "pause" as I help a friend spin up an awning and canopy biz) and chose to go with Sailrite because of their second-to-none customer service. I was a parachute rigger in the Corps in a former life and spent most of my time trying to keep Consews and other clutch driven machines running. The simplicity of the Sailrite LSZ-1 (DO NOT GET THE LS-1 if you want to do any sail repair as it doesn't do a zig-zag stitch) and it's portability is why I got it for my mobile shop trailer). In my big shop, I have the Sailrite 111. I intend to get a Fabricator as well in the near future. Another neat feature of Sailrite is their huge library of how-to videos, calculators, etc. Want to make cushions? They'll show you how. Want to build your own main-sail? They have a kit and a video for that as well. A lot of people in my industry hate Sailrite for just these reasons. Are their machines as fast and powerful as some of the big industrial level Consews and such? Of course not. But you'll be able to sew more and cuss less when it's time to change a needle, set the timing or replace a hook. And due to this and the AMAZING customer support and their promotion of all things nautical, Sailrite has earned my business and my loyalty. If you are just looking for the cheapest machine out there, than for sure look elsewhere. But in the long run, that cheap machine will end up costing every bit as much as an LSZ-1 from Sailrite.
Again, just my humble opinions based on years of experience. Good luck with whatever direction you choose to go!

[deisher6]

Hey Rick, sent you a PM asking for some sewing advice.
regards charlie

[AirborneJarhead]

Charlie,

I just replied to your PM...good luck!

[crazycarl]

I picked up a sewing machine for $35 to make new interior cushions.  After taking a couple sewing lessons from our daughter, I paid her airfare last year and in return she making the cushions.  If it was left to me, we'd still be sleeping on the originals. The kids an artist with that machine.