How to Measure a Chair to Make a Box Cushion Cover

In this video I will show you the following:

  • How to measure a chair to determine the cut size of foam
  • How to create a paper template for your foam
  • How to create a template for your fabric including seam allowances

For this project, I am using a 3” Ultra Medium foam with a 2.6 density and 35lb. compression.

This video does not include the cushion cover fabrication. That process can be found in the Boxed Cushion Cover video on the membership site.

This will include using cording/welting, boxing, and a zipper placket.

Supplies List:

  • Paper for template
  • 3” Ultra Foam 2635 (2.6 Density, 35lb. Compression)
  • 1.5oz. Bonded Dacron
  • Spray Adhesive


  • Marking utensil and note paper
  • Paper large enough to create template
  • Straight Edge 24” ruler or yardstick
  • Foam Saw or electric carving knife to cut foam
  • Paper cutting scissors