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Forum > Home Dec. Sewing > making a zipped odd shaped box type cushion ( Moderated by Sharon1952)

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making a zipped odd shaped box type cushion
making cowl plugs for aircraft using old ones
avatrx

avatrx  Friend of PR
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Posts: 538
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Date: 6/8/11 4:38 PM

I know this should be easy, but I've never made any type of box cushion or anything before.

I need to make new covers for the cowl plugs for an airplane because mine are all worn out and torn.

They are approx 8" x 6 inches and about 3 inches thick. The filling is a really firm outdoor foam. They're kind of a skewed oblong/oval size.

The old ones had a zipper across the back flat part of the cover which made it almost impossible to remove the foam insert. They also have a cord that runs from one to the other (they're a set of 2 - right and left sides) That I would just sew into one of the seams.

I'm hoping someone could advise me of how to go about this. I did kind of copy the foam onto tracing paper, measured the circumference around the outside on to tracing paper. I'm not really sure where to go from here.

How much seam allowance and what order do I put these together. I'd like to put the zipper in the box part of the plug so that it will be easier in the future to remove the foam and wash the covers. Should I just put the zipper in the long piece which I've cut to approximate length and width and then trim from there? I don't mind if the zipper shows so I don't need a flap over it.

HELP! Appearances are not the problem. Keeping the birds out is! :-)

TIA,
susie
ssarge@owc.net

clt3
clt3
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Ohio USA
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Date: 6/8/11 5:24 PM

I've used these directions for a box cushion before:

Sew a box cushion

------
Singer 66-16. Singer 600e, Kenmore 158.1913 , Viking 1100, Brother 4000D, Brother Quattro, Bernina 930, White 634DE,
Babylock Evolve, 2 Featherweights ,Pfaff Creative Performance,Janome Coverpro 1000CPX






Tom P
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Tom P  Friend of PR
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In reply to avatrx


Date: 6/8/11 6:58 PM

Are they prismatic? Like a cylinder or rectangular box? If they are, every slice parallel to the outer edge will have the same shape.

Do you need the covers to be waterproof or anything? Is there a lot of stress on the seams?

If the foam is prismatic, you can trace the end, then add a seam allowance. 1/2in. should be fine.

For the edges, you need a piece that is as long as the perimeter of the foam, and as wide as the foam is high. Add 1/2" seam allowance to all 4 edges.

The zipper closure goes into the long side. You can cut the side piece in half lengthwise and sew in the zipper if you want, or you can do a facing to make a rectangular hole to take the zipper. You can make the zipper as long as you want.

Sew the short ends of the side piece together, then sew the long edges to the ends. If you have no sharp corners, it should go pretty easy. You can turn the cover RS out through the zipper.

If the ends are different shapes, you can take a couple of crosswise darts on the short side to account for the shorter length of whichever end is shorter. You can cut the side on the bias if the difference is more than a few inches or if the foam is shorter than about 6in.

If you want the covers waterproof, you can use a coated fabric and waterproof zipper. Seams Great(R) will seal all your stitching lines.

If you need more info, posting the shape of the foam would really be helpful.

avatrx

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Date: 6/10/11 8:32 AM

THe foam is somewhat rectangular. If you took a rectangle and pushed down on it which results in the top being forward and the bottom sticking backwards, that is kinda the shape.

The covers don't have to be waterproof. My plan is to make them out of sunbrella fabric which is what the originals were made of. The foam is approx 3" thick. very hard foam.

over the years the foam is somewhat smooshed but still usable. I'd like the covers to fit somewhat tight, but isn't manadatory.

A cowl plug gets pushed into the two holes in the very front of the airplane - behind the prop. there are 2 sides strung together by a strong cord. The purpose of these is to keep birds and debri from getting into the engine compartment.

I'm guessing that since the shape is irregular, I can cut the boxing strip and just pull it tight once I have the zipper in?

Do I add the tops and bottoms after sewing the boxing strip to fit and hope the shape kind of 'falls in to place'?

(sorry it took to long to reply. I hadn't logged in because of a power outage here)

avatrx

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Date: 6/10/11 9:28 AM

I have a rough shape of what I'm trying to accomplish but I'm not sure how to attach it. I don't have a website. Due to economics I don't have a current PR membership. (hence the reason I'm trying to do my own makeover on the covers).

Here is a supplier of them along with a photo. Mine are just covered in sunbrella since I don't think my D1 would sew on marine vinyl. They don't have to be vinyl. this shows the approximate shape.

http://www.skycovers.com/item/root/piper-cherokee-pa28-160-plug-s/lid=3551582

Tom P
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In reply to avatrx


Date: 6/10/11 1:44 PM

Quote: avatrx
I'm guessing that since the shape is irregular, I can cut the boxing strip and just pull it tight once I have the zipper in?


I'm not 100% sure what you mean by this, but I'll take a stab.

If the foam is the same thickness all around (so the ends are parallel), you can design your finished boxing strip (with the zipper) to be a rectangle as wide as the cushion is thick plus two SAs. You can then wrap it around the cushions to get the length right. Make the zipper as long as you want. If the ends are different shapes, I'd cut the strip on the bias (maybe not for a seat cushion, but for this application, anyway).

I'd try to cut the ends of the cover by tracing out the shape and adding a SA. If you really want a tight fit, you can get the ends about the right shape, baste them on, then up the cover on the cushion RS out to see where you need to tweak the fit.

The welts are there to protect the seam from abrasion. I really wouldn't even bother with them.

It is possible to overthink this, too. Is it possible to cover the foam with what's essentially a drawstring bag with the drawstring toward the inside? Just trace off the exposed end, add a seam allowance, and make a bag that's 6" deep or so out of packcloth or nylon taffeta even, drop the foam in, then cinch it up (permanently) with the drawstring? I'm assuming that if you don't care if it's waterproof, you won't care if there's a little hole in the cover on the inside end of the plug.

That's just an idea.
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