Sewing Curved Knee Roll Cushions - The Ultimate Guide

Learn how to make a curved knee roll cushion that has a fabric backside. This cushion is made from two pieces of foam, one higher than the other. Because of that it requires a "fabric pull" to be inserted between the two foam pieces to help pull the seating vinyl down between the two foam heights. Since the backside is not a backer-board, but rather fabric, the fabric pull must utilize a zipper which is used to insert the high foam along the exceptionally curvy front.
Watch this tutorial video and learn how to:
1. Cut curvy high and low foam pieces for a perfect fit.
2. Adding a closed-cell foam bottom to keep cushion for soaking water in through bottom.
3. Using match-up marks to sew shapely fabric panels together for a great fit.
4. How to make and sew in a "Zippered Fabric Pull"
5. Sewing odd shaped boxing properly to the cushion's top plate.
0:00 - Intro
1:15 - Cutting High & Low Foam Inserts
5:59 - Creating Bottom Plate
10:59 - Creating Top Plate for Low Foam
15:08 - Cutting Top Plate for High Foam
18:42 - Creating Match-Up Marks for Plates
21:36 - Sewing High & Low Plates Together
29:37 - Fashioning Zippered Fabric Pull
32:55 - Sewing Fabric Pull on Plate Assembly
38:25 - Calculating & Cutting Boxing
47:58 - Sewing Boxing to Top Plate Assembly
1:09:12 - Topstitching
1:19:24 - Sewing Bottom Plate onto Assembly
1:24:44 - Inserting Foam
MATERIALS LIST:
CushionRite® Premium Antimicrobial Foam (Firm) - SKU: 124236 www.sailrite.com/CushionRite-... Flotation Antimicrobial Foam 1/2” (Extra Firm) - SKU: 124250 www.sailrite.com/CushionRite-...
CushionRite® Foam & Fabric Spray Adhesive 16.9 oz. - SKU: 125476 www.sailrite.com/CushionRite-...
CushionRite® Premium Foam (Medium) - SKU: 124234 www.sailrite.com/CushionRite-...
McLube™ Sailkote 8 oz. - SKU: 120679 www.sailrite.com/McLube-Sailk...
Cushion Underlining White 54" Fabric - SKU: 768100 www.sailrite.com/Cushion-Unde...
Lenzip® #5 White Continuous Coil Zipper Chain - SKU: 124597 www.sailrite.com/Lenzip-5-Whi...
Seamstick 1/4" Basting Tape for Canvas & Upholstery (36 yds.) - SKU: 122065 www.sailrite.com/Seamstick-1-...
Lenzip® #5 White Single N/L Delrin® Zipper Pull (Coil Chain) - SKU: 125127 www.sailrite.com/Lenzip-5-Whi...
Tex 90 Polyester Thread from Sailrite www.sailrite.com/search?keywo...
EverSoft™ Pebble Indoor/Outdoor Tan & Off White 54" Vinyl Fabric - SKU: 122212 & 122211 www.sailrite.com/Fabrics/Mari...
Fabric Backed Sew Foam 1/4" - SKU: 124306 www.sailrite.com/Fabric-Backe...
Lenzip® #10 White Continuous Coil Zipper Chain - SKU: 124599 www.sailrite.com/Lenzip-10-Wh...
Lenzip® #10 White Single N/L Delrin® Zipper Pull (Coil Chain) - SKU: 125129 www.sailrite.com/Lenzip-10-Wh...
Polyester Fiberfill 15 Denier - Hollow Slick Conjugate - SKU: 104467 www.sailrite.com/Polyester-Fi...
Cushion Wrap Silk Film 54" - SKU: 103933 www.sailrite.com/Cushion-Wrap...
TOOLS LIST:
Sailrite® Blade Foam Saw V2 with Carrying Case (110V) - SKU: 121244 www.sailrite.com/Sailrite-Bla...
1" Foam Hole Cutter - SKU: 123693 www.sailrite.com/1-Foam-Hole-...
Scribe-All® Black Marking Pencil for Vinyl - SKU: 121977
Sailrite® Deluxe Fabricator® Sewing Machine Package (110V) - SKU: 400600 www.sailrite.com/Sailrite-Del...
Seam Ripper Deluxe - SKU: 18104 www.sailrite.com/Seam-Ripper-...
Gingher® Scissors Right Hand Lightweight 8" - SKU: 101017 www.sailrite.com/Gingher-Scis...
Sewing Gauge Ruler 6" - SKU: 102995
Sailrite® Clear Acrylic Ruler 6" x 24" - SKU: 102400 www.sailrite.com/Clear-Acryli...
Fabric Edge Pattern Notching Tool - SKU: 124326 www.sailrite.com/Fabric-Edge-...
Deluxe Tape Measure 120" - SKU: 123120
Basic Thread Snips - SKU: 123222
Sailrite® Fabric Edge Match Pliers - SKU: 123498 www.sailrite.com/Fabric-Edge-...
Suisei Magnetic Sewing Guide - SKU: 102983 www.sailrite.com/Magnetic-Sew...
Left Edge Guide Foot Set 3mm for Sailrite® Fabricator® - SKU: 125123 www.sailrite.com/Left-Edge-Gu...
Sailrite® Battery Operated Thread Burner - SKU: 122432
Multiuse Pins 1-1/2" (250 pack) - SKU: 102985
Marker, Drill, Tape Measure, Heat Gun, Shop-Vac

[@dawnbowie352]

I don't sew marine cushions, but canvas and leather items for patios. So impressed with learning about the solutions to sewing on thick, curved items. Eric, you are humble when others make comments that differ. And you provide assistance to support those who offer other solutions. Great makers like you allow for everyone to learn, comment and find what works best in their situation. Love Sailrite DIY videos and their content gurus! ❤

[@SailriteDIY]

Thank you for your kind words and support! It's always great to hear that our videos are helpful to makers like you.

[@svbarryduckworth628]

Bravo Zulu! That does indeed look difficult. If you can do something like that you can do anything. Here I thought that just putting piping on a cushion was making things overly difficult. But we were very impressed that with the help of your videos we very successfully lined up the stripes on our striped fabric for our own settee cushions. Sailrite videos are the best in the DIY makerspace.

[@SailriteDIY]

Thank you for your kind words! We're thrilled to hear about your successful project.

[@Dontboxmein7]

Very informative as usual !

[@M_J_nan]

Excellent instruction and cudos to the videographer!!!

[@SailriteDIY]

Thank you so much for your kind words! I'm glad you found the instruction helpful.

[@davidkadams1]

Great job Eric.

[@SailriteDIY]

Glad you enjoyed it

[@ewjorgy]

Wow! Great video! I learned several tricks from this. I can't wait to drag out my LSZ and see what I can do! Thank you and all the best from California 🧡

[@SailriteDIY]

I'm so glad you found the video helpful! Can't wait to see what you create with your LSZ!

[@ewjorgy]

@@SailriteDIY Actually I have already made a boat cover for my 27 foot sailboat, an anchor riding sail, a mainsail cover, the drogue line kit that you sell, a mini split cover, cushions for my outdoor patio and a ton of other small stuff! I have learned an incredible amount from watching your videos! Not only do they teach proper technique they also show me how to employ new tools (that I may not have known about) and, of course, they inspire me! Thank you again for the amazing support and equipment that you continuously provide! P.S. the worker bee upgrade absolutely rocks! I LOVE it!

[@Willow2024]

YAY!! Thank you so much! Love learning from you, Eric:)

[@SailriteDIY]

I'm glad you're enjoying the content!

[@WatzTX]

Great video! Lots of relevant info and details. Very much appreciate the information!

[@SailriteDIY]

Thank you so much for your kind words! I'm glad you found the information helpful.

[@earthelder2065]

Great instructional video! Thanks a million. (James Leather Pensacola)

[@SailriteDIY]

I'm glad you found the video helpful! Keep learning and growing.

[@fordfan3179]

That's gonna be one of the first things I make when I get my leatherworking sewing machine......soon as they go on sale......I'm ok with scratch and dents to!

[@SailriteDIY]

Excellent. You will love your new Leatherwork Sewing Machine.

[@fordfan3179]

@@SailriteDIY .........when they go on sale, LOL

[@saltytailor]

As a Salty Tailor making boat cushions and canvas here in Sarasota, FL, I recommend NOT USING "cushion underlining" for a structural bottom plate. It rips very easy once a hole or small rip begins. It is far too weak. Mesh is still the best option for bottom plates of boat cushions. I know this after using this material a few years ago and having customers complain about it. And the many rip repairs I have had to do because of that material. YMMV 🤷🏽‍♂️

[@SailriteDIY]

Oh wow, I have not had that happen, but I will take your word for it. So... instead you may want to consider Phifertex or Phifertex Plus mesh or Textilene for the underlining fabric. Thanks for your recommendation!!!! Links for what Salty Tailor is talking about are below: www.sailrite.com/Phifertex-PLUS-Mesh-White-000-54 www.sailrite.com/Textilene-Sunsure-Vinyl-Mesh-White-54-Fabric

[@leilalineberger995]

What is this used for?

[@SailriteDIY]

These cushions are most often found on boats. The idea is the knee roll helps to keep the occupant in the seat when the boat is pitching back and forth. It is also very attractive in most peoples opinion.