How to Make DIY Seat Cushion Covers (for a Chair or Bar Stool)

Learn how to make DIY seat cushion covers for chairs or bar stools, with a simple method that looks custom without the high price tag.

These cushions add comfort, personality, and a polished finish to your space, and you can tailor them perfectly to your home.

I love browsing Pottery Barn for inspiration, but I usually leave thinking, I can make that! And you can too.

You’ll Love Making Your Own Cushions

There’s something so satisfying about creating a cushion from scratch. Not only can you choose the fabric, color, and size to fit your space perfectly, but you’ll also get a custom, professional-looking finish without the custom price tag. Yay!

This project is simple enough for beginners and rewarding for experienced, too. You can add comfort, style, and personality to any chair or stool in just a few steps.

Plus, once you make one, you might find yourself making one for every seat in the house.

If you want a fresh look or just want to breathe new life into an old piece, this is a great way to do it! It will be functional, beautiful, and made by you!!

Don’t miss all the other cushion projects on my site!

Materials

Gather the rest of your materials. Here’s what you’ll need. (Affiliate shopping links are included below)

Fabric for Cushions & Ties
Straight Pins
Matching Thread
Pencil with Eraser
Paper Scissors
Fabric Scissors orRotary Cutter
Snippers my absolute favorite!
Cutting Mat or safe surface
Omnigrid my favorite ruler/straight edge
Sewing Machine
Paper orCardboard for Pattern
Foam Cushion
Sharpie Marker
Electric Knife
Iron my cute new iron

Pattern

First, you’ll need to create a pattern template for the furniture piece you are working with. We will start by measuring your chair or bar stool.

For the pattern, any paper or cardboard will work. I chose a large piece of cardboard because it was stiff and would lay flat over the curved seat of the chair.

To ensure that my pattern was symmetrical, I cut out half of the cushion shape, flipped it over, and then repeated it.

You’ll want to take notes for all of your pattern pieces, with their corresponding measurements, to calculate yardage.

You’ll need five pattern pieces in total.

The top of the cushion, the bottom of the cushion, the side panel strip (based on the height of your foam insert), a back strip piece (this will act as an envelope flap for the back of your cushion), and two ties.

IMPORTANT: Remember to add a seam allowance.

This is the area between the raw fabric edge and the stitching line on the pieces of material being sewn together.

They can range from 1⁄4 inch (6.4 mm) wide to as much as several inches.

However, how wide you’d like to make yours is up to you. I typically use a 5/8 inch (1.5cm) seam allowance.

After that, decide on the cushion height based on the foam insert you will purchase.

Note the length of the ties you’ll need as you measure.

As you draw each shape on a piece of paper, add in all of the dimensions.

This process will ultimately help you determine how much fabric you need to purchase.

Take these dimensions or your drawing itself to your local fabric store.

Their staff will help you figure out the best way to lay out the pattern on the fabric and how much fabric you need.

Many fabric retailers have home decor departments with great upholstery fabric suitable for use inside or out.

I purchased my fabric at a discount fabric store, SR Harris. (FYI: Worth a trip if you visit the Twin Cities!)

Instructions

Below is a step-by-step tutorial to make your cushion.

Fabric Prep

It’s time to get your fabric! Consider the amount of use the chair or bar stool will get. You may want a washable or easy-to-clean fabric. You could also Scotchgard (affiliate link) the fabric to protect it further.

For added interest, you might want to contrast the fabric of your ties with your cushion.

Once you have your fabric home, pre-wash it if you intend to wash the cover later. This will prevent future-fit problems if your fabric shrinks.

Cutting Fabric

It’s time to cut out your fabric. Layout your pattern pieces. Think thoroughly before cutting.

Consider the direction of the pattern or stripes so they run the way you want and connect well to the other sides of the cushion.

Making Ties

Let’s prepare the ties first. With the right sides together, fold each tie piece in half lengthwise.

Stitch across the tie length and close one end, leaving the other open.

Turn the tie right side out and press. Pull each corner out with a pin, if necessary, to square it up.

Tuck the seam allowance under on the open end and press closed. Topstitch both ends to finish.

If you don’t have one long enough, you can sew multiple strips together by pinning the right sides of each end together and stitching.

If possible, try to have the seams in the back of the cushion. After sewing, press the seam(s) open.

Next, with the right sides together, sew the top cushion piece to the top edge of the side panel, all the way around the cushion edge.

Stitch both ends of the side panel together, so it is closed in the back.

Attaching Ties

Pin the middle of each tie to the back corners of the cushion.

Sew the tie to the cushion with a vertical line of stitching. Stitch again to reinforce.

Sewing Top Back Panel 

With the right sides together, sew the top of the back fabric strip to the bottom cushion piece between the dots.

Reinforce the dots on both ends by backstitching.

The tails of the back strip should extend just long enough to tuck into the cushion cover and hide the foam insert.

After you’ve stitched, press the seam open. Pin both tails on each end toward the center of the cover.

This is temporary, so they do not get caught in the stitching in the next step.

Ataching Bottom Panel to Cover

Now, stitch the bottom panel to the side panel, but don’t sew between the dots this time.

Remember to backstitch at each dot to reinforce the edges.

Most importantly, these areas need to be strong, as they get a lot of stress when you insert the foam pad.

Finishing

It’s time to iron your new cushion cover. Pull it over an ironing board if possible.

Press open as many seams as possible. This will give the cover a beautifully finished quality.

To press into the corners, use a tailor’s ham or a rolled-up athletic sock. Preferably clean. 😁

In the back, press the raw edge on the side panel flap under a quarter inch, so the raw edge is not showing.

Foam Inserts

Next, it’s time to cut your foam cushion to size. This is SO easy and actually kind of fun!

I purchased my cushions at Joann Fabrics. I paid roughly nine dollars per foam insert with a coupon.

The Airtex 2 x 15 x 17-inch size worked perfectly for my Pottery Barn bar stools.

I can always reuse the inserts and recover them as long as I own the chairs. 

Place the pattern piece for the top cushion directly on the foam insert.

Trace around the pattern perimeter on the foam with a Sharpie marker.

It’s also worth mentioning this DOES NOT destroy your electric knife. You can reuse your knife for food.

We received our electric knife as a wedding gift 30 years ago.

It’s seen many Thanksgiving turkeys, Easter hams, and a handful of cushions over the years. (Don’t tell my family.)

No worries, it cleans up well. 😂

Inserting Foam into Cover

It’s time to put your cushion into the cover.

Fold the foam in half, then flatten and gently tuck foam into each corner, smoothing the bumps as you go.

Keep working with it until it fills out the cover nicely.

The only advice I have is to take a deep breath. It requires a bit of finessing and lots of patience. You can do it!

Finishing Back of Cushion

There are many ways to close the back of the cushion. It’s completely up to you what you choose.

Since the back is typically not visible, you can do whatever is easiest for you.

If you plan to wash the cover, choose an easy closure to open, close, and remove the insert.

There are many options.

For example, you could sew Velcro strips or snaps to both sides of the closure flaps, add a zipper, and use safety pins or hand stitches to close.

Tufting Cushion

If you’d like to tuft your cushion, like adding a button detail in the center, see this wonderful video tutorial by Dritz. Click here

WA-LA, you are done. You now have a professional-looking comfy perch! Enjoy.