How to Make a Powerboat Lounge Cushion

X-HT-200704

Our Powerboat Makeover project, a 1982 Regal Ambassador 245XL, has a lounge bench seat built right into the fiberglass. It was originally covered with three cushions to accommodate the curved shape of the bench. As part of our refit of this boat, we reupholstered all of the cockpit seating.
Video Chapters:
  • Patterning – 1:10 min.
  • Patterning Back Plate – 6:14 min.
  • Patterning Top Plate Sections – 8:20 min.
  • Sewing French Seam – 12:32 min.
  • Sewing Channeling Fabric – 16:38 min.
  • Finalizing Top Plate Size – 22:13 min.
  • Making Boxing – 25:25 min.
  • Sewing Prefabricated Piping – 33:17 min.
  • Installing Zipper & Snap Straps – 38:00 min.
  • Joining Boxing & Sewing to Plate – 44:34 min.
  • Sewing Bottom Plate to Assembly – 54:42 min.
  • Patterning, Cutting & Gluing Foam – 57:28 min.
  • Installing Snaps to Straps – 1:07:17 min.
  • Materials List – 1:11:11 min.
Materials List:
  • Filament Strapping Tape 3/4" – #5643
  • Seamstick 1/4" Basting Tape for Canvas & Upholstery – #104167
  • Cushion Underlining Fabric – we used Beige, #103934
  • Morbern™ Seabrook Stinger Bisque 54" Vinyl Fabric – #105978
  • Morbern™ Seabrook Midnight 54" Vinyl Fabric – #105987
  • EverSoft™ Smooth Off White 54" Vinyl Channeling Fabric – #125231
  • Polyester Grosgrain Ribbon Webbing – we used Tan, #PLGGTA
  • Morbern™ Seabrook Vinyl Welting/Piping – we used Midnight, #120144
  • YKK®#5 White Style A Single Non-Locking Delrin® Zipper Pull (Molded Tooth Chain) – #103178
  • YKK® #5 White Continuous Molded Tooth Zipper Chain – #28218
  • White Nylon Webbing – #NYLWWH
  • CushionRite® Dry Fast Antimicrobial Foam (Medium) – #124203
  • SnapRite® Snap Fastener Button 11/64" (Nickel-Plated Brass) – #104151
  • DOT® Snap Fastener Normal Action Socket (Nickel-Plated Brass) – #333050
  • 3M™ General Trim Spray Adhesive – #73211
  • Masking Tape, Cardboard
Tools List:
  • Dura-Skrim® Patterning Material – #103134
  • Gingher® Scissors Right Handed – #19104
  • Grease Marking Pencil Yellow – #111002
  • Sailrite® Clear Acrylic Ruler 6" x 24" – #102400
  • Tape Measure 120" – #102986
  • Sailrite® Ultrafeed® LS Walking Foot Sewing Machine – #311502
  • Sewing Gauge Ruler 6" – #102995
  • Suisei Magnetic Sewing Guide – #102983
  • Sailrite® Edge Hotknife Package (110V) – #103800
  • Sailrite® Blade Foam Saw V2 with Carrying Case – #121244
  • Multiuse Pins 1-1/2" – #102985
  • Sailrite® SnapRite® System (4 Dies & 100 Mandrels) – #104237
  • Pres-N-Snap Installation Tool – #109011
  • Yardstick, Marker, Pencil, L-Square

How to Make a Powerboat Lounge Cushion

When it came to this lounge cushion we decided to create one long, curved cushion that would both look and function better than the original design. If you have a similar cushion on your boat, this video will show you how to carefully pattern and sew a cushion with shape.

How to Make a Powerboat Lounge Cushion Video 2

Brian, a manager at Sailrite® and the owner of the boat, chose a classic color palette for his cockpit that consisted of three colors of Morbern™ Seabrook Vinyl: a Lite Glacier channeling fabric, and Stinger Bisque and Midnight standard vinyl. He envisioned all three of these colors being used together on the cushions with a decorative design. For this lounge cushion, we patterned a section of each of the three fabrics and seamed them together with a decorative top stitch called a French seam for a professional finish. We carried this design across all the seating in the cockpit, which you can see in the companion videos in this series.

To create the shape of the cushion we carefully patterned the fabric and the foam on the boat. The cushion cover was made to mimic the shape of the boat’s bench. The foam inside is actually three pieces with angular edges glued together to create a smooth curve.

In this video you will learn how to pattern for a curved lounge seat, create a multifabric cushion, sew a French seam, add snap straps and pattern curved foam.

This project is part of our Regal Ambassador 245XL Powerboat Makeover series.