DIY Network

Cushion Upholstery and Attaching Seats The barstool seats are upholstered and attached. From "Freeform Furniture" episode DFFF-110

In this segment host Amy Devers completes the Barstools by demonstrating how to upholster the cushions and then attaching the seats.

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	Host Amy Devers finishes the Barstools by upholstering the seats.
	Amy's completed barstools!

Materials:

Mild steel metal tubing
Upholstery fabric
Welding jacket
Ear plugs
Tape measure
Angle iron
Pen
Filler rod
80-grit sanding disc
Welder's angle clamp
Argon gas
Welding gloves
Clamps
Safety glasses
80-grit grinding disc
120-grit sanding disc
Rag
Degreaser
Cardboard
Rubber gloves
Respirator
Plastic cup
Synthetic steel wool
Poster board
Muslin
3/4" plywood
Electric turkey carver
2" dense foam
Spray glue
Bonded polyester batting
Cambric
Screws
Upholstery staples

Tools:

Metal chop saw
Face shield
Socket wrench
TIG welder
Disc sander
Angle grinder
Random orbital sander
Pneumatic stapler
Screw gun
Gun blue

	Figure A
	Figure B
	Figure C
	Figure D

Cushion Upholstery and Attaching the Seats

1. Make a pattern out of poster board for a muslin box. Use that pattern to cut and sew the panels of a muslin box (figure A) the exact size of the cushions you want.

   
   

2. Use the pattern to cut and sew the panels of the show fabric.

   
   

3. To assemble the cushion, start with a piece of 3/4" plywood the same size as the seat.

   
   

4. With an electric turkey carver, cut a piece of 2" dense foam (figure B) the exact same size as the plywood.

   
   

5. Use spray glue to attach the foam to the plywood.

   
   

6. Cover the whole thing with a thin layer of bonded polyester batting.

   
   

7. Stretch on the muslin box nice and tight (figure C). Staple it on the underside using a pneumatic stapler and upholstery staples.

   
   

8. When you are stretching the muslin, make sure you get out all the creases, dimples, lumps, and puckers. By doing this, your show fabric will go on like butter!

   
   

9. Stretch on the show fabric box and staple it on the underside with the upholstery stapler making sure to smooth out any wrinkles.

   
   

10. Lay on a layer of cambric (figure D). Cambric is a fine spun cotton that is typically used on the underside of upholstery projects. Staple all around the perimeter to cover up any loose ends.

    
    

11. Once the cushion is done, all that is left to do is attach it to the barstool.

    
    

12. For the final step, connect the frame to the base.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Power Tools (Porter Cable)
Porter Cable Power Tools
Website: www.portercable.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Ulmia GmbH
Website: www.ulmia.de

Woodcraft
Website: www.woodcraft.com

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Gun Blue
Shooter Solutions
Website: www.shootersolutions.com

Miller Manufacturing Co.
Website: www.millerwelds.com

Welding Tools and Accessories
Steiner Industries
Website: www.steinerindustries.com

Smith Equipment
Website: www.smithequipment.com