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Vanlife Build: Making our own dinette cushions

Note: we had a website glitch, so you may be seeing this for the second time.

Tim: When we decided that we would be building out a dinette/bunk, we knew that we’d have to have some cushions made. Because we modeled our dinette after the one in our Volvo semi tractor, we figured we’d at least see what the Volvo dealership wanted for theirs. And that number was $300 each, for a total of $1200. Ouch. But at least we had a starting point to start getting bids from local upholsterers.

Aaaaaand, that’s where things got worse. I could write a book on the effects of COVID-19 on this build, and getting quotes for these cushions continues that theme. First, everybody was booked solid for 6 months. Apparently, I’m not the only one with enough time on their hands to contemplate all of their projects. And second, this supply and demand imbalance means that everyone wanted premium prices. The BEST quote I got was for $1500! FOR FOUR SIMPLE CUSHIONS!! I could BUY a sewing machine, and make them myself for a fraction of that!

Wait a second. Duh. Of course I could do that. Most of my time in the military was spent as a Parachute Rigger. Part of that job was working with industrial sewing machines for all sorts of projects. And I was damn good at it. From backpacks, to travel bags, to wheel covers, to simple repairs; they didn’t call me the Lead Stitch Bitch for nothing.

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My new whip. Note the PCT map in the background.

This opened up all sorts of possibilities. First, I looked up reviews for heavy duty sewing machines. After wading through all the options, I settled on the Singer 4411. (Actually, I wanted the next model up, but COVID strikes again: no availability for 6 months). I sourced it from JoAnn Fabrics for $240.

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cushions

We worked with a company called the Cushion Source. All we had to do was give them our exact dimensions (42×19.5×6), and choose the quality of cushion we wanted. We went with a mid level foam cushion with an inch of soft batting on both surfaces. These were $64 each. For comparison’s sake: plain jane cushions start at about $25 each, top-of-the-line ones with memory foam can go for $125 each.

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Next, we had to choose the style of fabric we wanted. We had a very loose interior design in mind: ocean breeze. So there would be a lot of blues, greens, aquas, grays, etc. Cushion Source had a dizzying array of choices, and we ordered some samples from them. Ultimately, we went with the stripes you see above. I needed about 6 yards of stripes, and 3 yards of the blue to cover the cushions, all in their “Sunbrella” style of indoor/outdoor fabric. This cost around $250.

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Next, we needed zippers. I wanted them to be long enough to run more than the length of the cushions, in order to make sure it was easier to remove the foam from the covers. These were 45″ long, at $7 each from JoAnn Fabrics.

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After that it was just a matter of tacking it all together. I cut the slit for the zipper, hemmed it, then sewed in the zipper. The top and bottom pieces were attached to the zipper piece. After some minor adjustments, they seem to fit fairly well. And then it was time to put them into the van:

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Not too bad.

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Post script: I noted above that I paid $240 for the sewing machine. I am NOT including this cost in the overall budget for this van build. My reasoning is that, while I bought it because of this build, I can use it for anything unrelated to the van. Conversely, I’ve applied this logic to the tools I have bought as well. I tried to borrow what I didn’t have, but ultimately, I have sunk a significant amount of money into a couple of power tools, nail guns, etc. Not that it matters, I’ve already blown by my initial budget, so what’s a couple hundred dollars among friends, right?

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