BOAT RESCUE, PART 14: UPHOLSTERY TIME.

Previously: PART 13: A BIT OF EVERYTHING

With the cooler weather here again it was time to line up an indoor job for a few days. I've had my roll of upholstery fabric for a while, sitting in the basement waiting for some attention.

The first pieces made were the six settee cushions, using super soft foam for filler and covered with an acrylic fiber fill for a bit of extra padding. The fiber fill also makes stuffing the foam into the cover easier.

Cutting fabric, with  windows open and fan on, using a hot knife to prevent fraying,

Because the fabric has a lot of longitudinal fibers, my first attempt cutting it with scissors resulted in a lot of frayed ends coming loose, making it hard to sew. I was concerned the fraying would spread over time and weaken the seams. Using a hot knife solved the problem nicely.

After the first successful cushion I was confident enough to start mass production. Stitching along the fabric lengthwise was easy as the stripes provided a guide. Going across, I used a chalked line for guidance.

Pieces ready for assembly

Stuffing in the foam.

Sailrite supplied the zippers and slides (all plastic), as metal zippers and slides don't fare well in a salt water environment. The Foam Factory supplied the foam.


Sewing on the zippers.



Stack of three settee cushions.

The mattress for the quarter berth is 3 inches thick, matching the original. But the two settees will get 4 inches of firm foam as they will be the most used seating and sleeping areas.


Laying out the quarter berth mattress

Cutting out the basic shape.

Beveling the edge where it fits against the hull.

Finished quarter berth foam.

The final test: ahhhh ... three inches thick is plenty!

As soon as the rest of the foam arrives the settee cushions can be finished. We've decided not to upholster the V-berth at this time as it'll be used for storage, like the one on our Vega. The wood deck on the Vega V-berth is covered with a rubber-backed durable carpet that keeps things from sliding around too much. I'll do the same on the Ballad. However, there's enough fabric left on the roll to do the V-berth if we change our minds.

Now it's time to get back out to the boat shed and start wiring!

Next: PART 15: PLAYING WITH LED STRIP LIGHTING