Cockpit Cushions - Again

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Starscream
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Re: Cockpit Cushions - Again

Post by Starscream »

Bump.

After having (almost) completed the cabin cushions, now I'm planning the cockpit cushions. I enjoyed the results of the cabin cushion project, even though it was frustrating at times. I read everything I could find on cockpit cushions on the fabric websites, this thread and the forum archives. At this point, I'm leaning towards this shopping list:
Image

(CDN dollars) (The terylene and piping are sold per foot, the fabrics per yard)

Thought process as follows:
I hear the positives of closed-cell foam, and the negatives on the firmness of dry-fast. The foam product on my shopping list is polyester, while the dry-fast is polyurethane. I hope that will make a difference on softness. I'm not convinced whether or not I want 3" or 4" foam, but I think 4" will be more comfortable for lounging, which we do a lot of.
So, the Sunbrella with a 303 coating will be used as tops and sides. This will prevent beer and other liquids from entering the foam from the top. The bottom will be Phifertex mesh, covering the non-wicking cushion foam and the non-wicking Terylene padding. The idea is to make the bottom panel as "open" as possible so that any collected water can air out. The foam and padding are non-absorbent, non wicking, and mold/mildew resistant.

I read the concern about the piping not working in the long run, but I really like the look and am willing to give it a try with heavy-duty UV thread and a tight stitch pattern. I'm thinking black sunbrella with white piping, to match the racoon stripe and sailcovers. I'll use the black 8-oz UV thread that I already have from my sail-cover project, and #5 YKK Vislon zippers.

I am probably going to add a strip of velcro along the edge of the bench cushions, where I can velcro on a sacrificial "boarding mat" made from a rectangular sunbrella piece that can be easily removed, rolled and stuffed behind, or replaced.

Gonna go back to work for a few weeks first, though, so progress won't be immediate. Any and all feedback appreciated as always.
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NiceAft
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Re: Cockpit Cushions - Again

Post by NiceAft »

What I have come to learn from fifteen years of black Sunbella cushions over high density foam is:
(A) Sunbrella fabric doesn’t let water touch the foam.
(B) The high density foam is quite comfortable, especially if you wrap the foam in Dacron.
(C) I made the cushions with Sunbrella on both sides so they are reversible.
(D) After fiffteen years, the cushions are still quite good.
(E) The black Sunbrella is quite comfortable in the sun. The Admiral has never complained.
Ray ~~_/)~~
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Starscream
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Re: Cockpit Cushions - Again

Post by Starscream »

Hi Ray,

Your contributions are making me consider the all-sunbrella route, sealed with 303 for added water-tightness, and I still may change my plan to that one. My concern with that route is the zipper, cuz any water or beer that DOES get in will have just as hard a time getting back out. Kinda like my current, original vinyl cushions. They are still ok after 19 years, but only if you don't look inside. They get truly soaked at dozens of times per year (more from kids climbing through the cockpit to jump off the cabin-top than waves, spray, or rain, but those happen too), and take forever to dry when they do, and now the foam, while still functional, is gross. How is your foam doing? Do your cushions get soaked regularly?

So the idea is to open up the bottom panel to allow air circulation through non absorbent foam. That seems to be the consensus among the sewing websites.

I like the reversible idea, but the X cushions aren't symmetrical shapes, there's a left and a right. So I don't have the reversing option available.

I think black is the right color for us. Up here in Canada, we fight for the sunny patch to sit in 95% of time, and warmer cushions will be welcome. We don't complain if our cushions ever get too hot to sit on, we just think of the snow coming in a few short weeks and shut up to enjoy it while it lasts...
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NiceAft
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Re: Cockpit Cushions - Again

Post by NiceAft »

I thought an interior examination might help.

You can see the odd shape of the cushion. Both cockpit cushions are the same, just opposite. I flip them. I am not familiar with the :macx:, it may be different than the :macm: .
Image

Original foam and Dacron from 2005.
Image

The zipper.
Image

I am having cushions made in the same manner for the seating area of our fire pit, only in yellow. That’s how confident I am.
Image

P.S. I forgot to add that along with the template I made of the seat cushion, I also made one of the seating area’s back. I have two long back cushions for that area. Those are not box cushions, they are knife edge.
Ray ~~_/)~~
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Starscream
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Re: Cockpit Cushions - Again

Post by Starscream »

Huh, temptinger and temptinger.

My cushions snap on to the seat tops, so flipping them isn't really an option. It looks like the M velcros in along the zipper line so neither top or bottom face snaps in there.

I have a convo going with JT's Outdoor Fabric, well playing phone tag anyway, so I'm interested to see what they say. Now I have to you-tube knife-edge cushions.
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NiceAft
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Re: Cockpit Cushions - Agai

Post by NiceAft »

Knife edge cushions are thin, and will not give the comfort you are looking for in the seat, but will be more than adequate for back cushions.
Ray ~~_/)~~
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Re: Cockpit Cushions - Again

Post by Inquisitor »

NiceAft wrote: Mon Jan 18, 2021 6:28 am I thought an interior examination might help.
Image
Totally love the rockwork in your cockpit. You must have removed the steering column for that fire pit though. :wink:
Odysseus, expert on the Siren's call
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NiceAft
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Re: Cockpit Cushions - Again

Post by NiceAft »

Inquisitor wrote: Tue Jan 19, 2021 6:08 am
NiceAft wrote: Mon Jan 18, 2021 6:28 am I thought an interior examination might help.
Image
Totally love the rockwork in your cockpit. You must have removed the steering column for that fire pit though. :wink:
Switched it for a tiller :P :wink:
Ray ~~_/)~~
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Re: Cockpit Cushions - Again

Post by Inquisitor »

OUCH!!!

Even in Yen that hurts. I don't recall how much I paid for the optional Mac cushions, but I'd have taken a hard pass if it was anywhere near half this.

I know its not Sunbrella, but its wear number of 100k double-rubs and a light fastness rating of 3000 hours. I have samples of this coming to evaluate, but to recover the stock foam cockpits seats I was only looking at about $40.
https://revolutionfabrics.com/collectio ... oor-fabric

DID I JUST MAKE CAPTAIN? - Drinks on me!

Starscream wrote: Sun Jan 17, 2021 5:44 pm (CDN dollars) (The terylene and piping are sold per foot, the fabrics per yard)

Image

...
Odysseus, expert on the Siren's call
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Re: Cockpit Cushions - Again

Post by Inquisitor »

The problem I have in picking out a foam (like many of you have noted already) is not just type (closed, open, quick dry) but being able to try out before I purchase it from places like https://www.thefoamfactory.com/

Maybe as a baseline, does anyone know what the foam is in the stock cockpit cushions? Not just type, but don't I have to pick a density also? Is the foam inside the cabin seats and berths the same? I'm sure the back cushions is different... what's that stuff?
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Re: Cockpit Cushions - Again

Post by Russ »

Taking Ray's advice when redoing cockpit cushions, I went with black sunbrella. He's right about the color not getting hot in the sun. My sail cover and dodger are never hot.

But I got creative and went with Charcoal. This has some "recycled" material that I thought would make it more forgiving for spills. BIG mistake. Whatever is in this product DOES get hot. Not scorching like the factory beige but it does get hot. Should have listened to Ray and just went plain black.

https://www.sailrite.com/Sunbrella-1800 ... ure-Fabric


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--Russ
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Re: Cockpit Cushions - Again

Post by NiceAft »

If using Sunbrella (I can't speak about other mfg's), be certain to use an "outdoor" fabric. It may be classified as suitable for upholstery, but be certain to look for the outdoor classification also.
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Re: Cockpit Cushions - Again

Post by Starscream »

This cushion-making thing is addictive. After supper I just wanna come downstairs and whip out a new one. So I did. Using some leftover Sunbrella from the sailcover and leftover foam from the cockpit project, I whipped out a full-sunbrella, high-density foam captain's seat cushion. I added a flap over the zipper to see if that would help waterproof the thing, and it looks like it really will. I didn't spend a lot of time making it pretty, I just whipped it out to see what the final product may look and feel like.

I used 3" high-density Curon foam. It's too hard for my taste and comfort. The real project will use the 4" outdoor cushion foam I linked to before. I spoke to someone at the supplier and they said I might find the outdoor foam too soft, but I want soft. Sunbrella is a lot harder to sew around the corners and get a good result. The soft fabric I used for the interior was much more forgiving.

I posted the wrong 303 protectant in my shopping list up above. Sunbrella needs 303 fabric protector, Vinyl takes the 303 Aerospace protectant that I had in my cart. Live and learn.

Image

I tried rounded corners and only two pieces of boxing - one for the zipper in the back and then a long one all the way around. I don't like the look as much as using 4 pieces of boxing, but I guess it makes sense to have fewer seams in a cockpit cushion. Decisions...
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Re: Cockpit Cushions - Again

Post by NiceAft »

I admire your tenacity in getting cushions done. I would have just found an upholsterer. :D
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Re: Cockpit Cushions - Again

Post by Starscream »

NiceAft wrote: Wed Jan 20, 2021 6:21 pm I admire your tenacity in getting cushions done. I would have just found an upholsterer. :D
Hahaa yeah...I thought about it.

We are stuck in quarantine with all non-essential businesses closed, with an 8pm to 5am curfew, and it's cold as $%$% out there, so cushions it is!

Plus, I somehow enjoy it. It's like building a shed, only it's cushions, but with a similar feeling of success when you're done. (I'm not giving up my man-card!)
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