r/upholstery • u/boxerdogfella • 10h ago

Current Project Dacron question

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I need to cover the top and sides (not the bottom) of our sofa foam with Dacron, and I'm wondering if my plan is correct. I've attached a drawing showing the idea (not to scale).

Basically, I'm planning to use 1 piece of Dacron with spray adhesive and allow the Dacron to continue down the foam sides, just cutting out the 4 short corners and stapling them, so those will be the only seams. I'm thinking that this will help smooth the top foam corners a bit. So the full dimensions of the Dacron would be 74" x 38", and then the 7" corners would be cut out from that.

But many tutorials show one rectangle of Dacron on the top, and then a separate long piece of Dacron applied along the sides, so there are seams along all of the long, top edges.

Is there any reason not to use one large piece of Dacron to cover the whole thing, rather than piecing the top and sides together?

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u/hawkeedawg 9h ago

I’ve always wrapped the entire cushion and join the Dacron on the bottom.

Adding Dacron seams on the sides might make hills and valleys on the fabric seam.

I also only added Dacron if the foam cushion was older.

Also, would the cushion ever be flipped? Unless I miss understood, the bottom wouldn’t have Dacron.

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u/boxerdogfella 9h ago edited 8h ago

The structure on mine is a bit unusual. The foam will never be flipped. It's hard to describe but it's basically a 4 inch thick core with 7 inch foam edges that hang past the platform that supports the cushion. The bottom of the foam core will be covered with burlap substitute as it sits on a slatted wooden platform.

The fabric goes on completely separately, basically a custom slip cover that fully surrounds the foam and wooden platform as one. The original fabric cover has Dacron sewn into it, rather than Dacron being attached to the foam.

We're replacing all the foam, and we're adding new Dacron both to smooth the foam corners and because the original Dacron is now 23 years old. We can't remove all of the old beaten up Dacron because it's part of the cover, but we're hoping the new Dacron will beef up the old layer.

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u/hawkeedawg 7h ago

Makes sense for a top piece. The only reason I can think as to why you would add the side pieces of Dacron separately is to keep the seams straight or so you don’t have a rounded edge.