- 1). Learn all you can about foam. For starters, it's a good idea to buy foam that's fire resistant (FR) and high resilient (HR)--the latter designation means the product will last longer. Then consider the indentation load deflection (ILD), which tells you how firm the foam will be. Firmness is a personal choice, but a lot of people like their back cushions softer than the ones they sit on. Finally, there's density, which is different than firmness. Higher density means a heavier, more expensive foam that holds up better than the lower-density stuff.
- 2). Order precut foam--or, if you're handy, cut your own cushions from a solid piece of foam. For the best results, draw a line to guide you, and cut with an electric serrated knife or a circular saw. If you're going work on many foam projects, consider buying a special saw for the job (see Resources). For safety's sake, go slowly with any saw or knife, and keep your fingers out of the way.
- 3). Fold Dacron wrap around the foam cushion, and attach it with a foam glue adhesive. This softens the edges so the final cushion looks more professional. This layer has another purpose as well: You'll find it's easier to insert the wrapped foam into the cushion cover.
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