Sewing How-To: Fixing Shredded Inner Cushion Covers by Sewing New

At least once a year, we all pull off our sofa covers, toss them in the washer, let them air dry and then zip them back on. This year, though, I found the inner covers on a few of the cushions have finally bit the dust. I knew I had to deal with this shredded inner cover this year… Today’s post shows how to make them like brand new!

Totally shredded, man!

Yes, these inner covers have seen better days and it is time to sew new ones. Thankfully, a friend in Scouting gave me an entire bolt of heavy cotton fabric so this new cover cost $0.00 ~ my kind of project!

How to Create New Inner Sofa Cushion Covers

• Measure the top and bottom (if different sizes), each side and any odd pieces ~ I like to create drawings (not pictured) and list the measurements on them. Add 1/2″ to each edge for the sewing selvage.

• Cut out each piece and prepare to assemble.

Pro tools

**If you own a “French curve,” use it to draw the curve of your sofa cushion. Literally, move the curved part of the tool until it matches the original sofa cushion’s curve. This is what you mark onto the new piece of fabric. Add the seam allowance along the edge and cut along that second line, like with any pattern.

The other quilting rulers shown above gave me the measurements for where the curve began and ended, plus seam allowances. I thought you’d like to see this layout. 🙂

Another pro tool you may wish to buy from your favorite website is called a “sewing ham.” When I was in a Creative Clothing & Construction class in college, the instructor had a source for sewing hams and we were able to purchase these “inserts” for holding out shoulder seams or for points on collars for ironing. The latter is a pointed wooden piece I only use in clothing construction; however, these two “hams” I use all the time in home decor sewing.

Both are covered in this plaid wool and the “ham” is underneath the cushion cover holding out the squared end as it is ironed.

This is the first time I really understood how to use the French Curve when creating a “curve” on fabric. You can see the sewing line measurement along with the cutting line (right hand line) in the photograph above.

• I cut out a rectangle of fabric, then measured in for the 5″ needed for the top and bottom pieces (included seam allowance), moved the curve (plus seam allowance) and drew the curve onto the fabric for the cutting line using pencil. Tailor’s chalk also works well for this, but pencil works fine, too, and will wash out easily with a pre-treatment (like Spray-N-Wash).

This second photo shows me checking the curve against the original sofa cushion.

• Cut out the top and bottom cushion pieces with added 1/2″ seam allowance all around the edges. Lay it on top of the actual cushion checking for accuracy.

**Why am I stressing the “seam allowance” info? For all the times I’d forget to add a seam allowance and I want to save you the trouble. 😉

• Begin with the top piece by sewing-on any identifying sofa manufacture stickers. I cut this tag off of the original cover and sewed it onto the new cover, albeit on the inside since I pinned it to what became “inside” of the cover. Goofs happen and the sewing job was beautiful, so I left it. 😉

Our sofa was built by Hickory Chair Company a little over 20 years ago, and we have owned it that long. Time flies!

• Sew all the side pieces to each other, except for the “back part” (shown below) as we are going to double it up ~ this makes it easy to slip the cushion into the otherwise really tight cover you are creating.
• For the back side pieces, you’ll cut two identical sections. I doubled the fabric over and sewed it to the seam ~ this creates a nice finished ironed edge with an opening along the top and bottom back. This makes pulling it over the sofa cushion soooo much easier! You can add button holes or a zipper, if you like.
• I closed the back with safety pins. (Quick and easy and you’ll never feel them and it’s an inner cover so a zipper isn’t really necessary.)

• Sew the edge pieces to each other, then sew this curved section of the top piece to the matching edge section, clipping the curve for flexibility after it is sewn. When placed on the cushion later, this will help it to fit better.
• Continue sewing on the other edge pieces around the new cover top until getting to the bottom (the actual “back” of the cushion where it meets the sofa seat bed).

For this back section, I also made it about 4″ longer, to hide the edges “around the corners” inside little “pockets.” This helps give more room for pushing/pulling the cushion inside the new cover.

• Once the top piece is sewn to all of the side pieces and to the first back piece (of the two), begin sewing the bottom piece to the side pieces.

I found it’s fun to pin the bottom piece to the side pieces while watching t.v. 😉 You can see where this cushion will go back once it is finished…

• Sew on the second back piece to this bottom piece, then sew it to the corners/sides creating the “pocket” on the outside of the finished piece. Iron all the seam allowances then turn right side out.

• Pull on the new inner cushion cover and voilá! Your cushion is almost complete!!

If you ever sew a cover with a zipper at the back of any cushion you make, these “pockets” really help hide the zipper pull “tang” and the zipper “stop” at the bottom of the zipper.

I left the original inside cover on the cushion, like some upholsterers do when working on antique sofas and chairs ~ as kind of showing the “history” of the piece. The original cover also holds the feather batting inside so I didn’t have to mess with that falling apart while pulling the new inside cover on.

As you work the new inside cover onto the cushion, reposition the batting and torn pieces to keep the cover from developing lumps. Finish with safety pins, button and button holes or with a zipper, if you prefer.

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Why is this cover a little big at the back?

I measured the original cushion cover and used that cover’s measurements for this project. The idea behind it being a little big is that when I go to have these cushions remade, I won’t have to pay for new covers and they will be ready for new really comfy, fully-stuffed cushions once again as large as the originals.

That’s my goal anyway. 🙂

We also need to see if the three-seater part of this L-shaped sofa can be remade on it’s left side with the other L’s “arm.”

I am thinking it can be done.

Any designers out there know if this can happen?? Part of me is almost willing to pull up the sofa cover and see what I can see. Maybe we could do it ourselves?? We do most everything else, so why not?

And here is the cushion all put back together and back on the sofa! The sunlight off my camera lens is making a dirty shadow on the cushion, so sorry about that…

The red cushion cover looks good now and feels much firmer with its new inner lining. I am very happy with this project! Time now to make a few more. 😉

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Happy sewing, my friends,