How to Make Covers for Outdoor Cushions - Outdoor Cabinets

Outdoor cushions can add a lovely pop of color and comfort to your patio, deck, or porch. However, the cushions themselves need protection from the elements to stay looking fresh. Making your own cushions covers allows you to customize them to your style and space, while saving money compared to buying premade outdoor cushion covers. With some basic sewing skills and weather resistant fabrics, you can create durable and stylish outdoor cushion covers perfect for your space.

Choosing the Right Fabrics for Outdoor Cushion Covers

When making outdoor cushion covers, your fabric choice is crucial to durability and longevity. The fabric needs to stand up to sun, rain, wind and dirt without fading, tearing or becoming moldy. Consider the following fabric options:

Acrylic

Acrylic fabrics are a great choice for outdoor cushions. Acrylic is fade resistant, fast drying and weather resistant while still feeling soft. Opt for an acrylic canvas fabric in a tight weave. Acrylic cushion covers can last for years outdoors.

Polyester

Polyester is another common fabric used in outdoor cushions. Look for polyester with a UV resistant treatment to prevent fading. Polyester repels water and dries quickly. A polyester with a Teflon coating offers even more water resistance. Polyester cushion covers hold up well outside.

Olefin

Olefin fabrics like Sunbrella are solution dyed, meaning the color is part of the fibers not just a surface dye. This makes olefin fabrics ultra fade resistant. Olefin fabrics are also mold, mildew and UV resistant. Olefin cushion covers are on the higher end but stand up excellently to weather exposure.

Cotton/linen

Natural fabrics like cotton and linen look beautiful on outdoor cushions but won’t last as long outside. They absorb moisture and fade more easily. Opt for an acrylic blend fabric with at least 50% acrylic to get the natural fabric look with added weather protection.

Vinyl

Vinyl coated fabrics are waterproof and stands up to rain, snow and sprinklers. They are a great budget option for poolside cushions. Look for vinyls with UV inhibitors. The downside is vinyl can feel hotter and crack over time.

No matter what fabric you choose, always select options specifically designed and treated for outdoor use. Avoid any fabric prone to mold or mildew. With outdoor cushion covers, durability should be the priority.

How to Measure Outdoor Cushions for Covers

Before sewing your covers, you need precise measurements of your cushions. To measure:

Lay the cushion flat on the ground.
Use a flexible cloth or vinyl tape measure. Metal tape measures may not bend and curve with the cushion shape.
Note the cushion’s length, width and height at the thickest point.
Also measure any ties, straps, zippers or other closure features on the existing cover.
Add 1-2″ ease to the length and width measurements for a smooth fit over the cushion. More ease may be needed for thicker cushions.
Write down all measurements for easy reference as you cut fabric.

Measuring carefully ensures a tailored cover that fits snugly over the cushion. Loose covers look sloppy and will allow rainwater to pool. Take time on this step for the best results.

How Much Fabric Do You Need?

To determine fabric yardage:

Calculate the surface area of the top and bottom of the cushion using the length x width.
For the sides, multiply the height by the perimeter of the top and bottom panels.
Add an extra 12-18″ of length for seams, closures and handling.
Divide total inches by 36″ to get the yardage needed. Round up to the nearest 1/4 yard.

Buying a little extra is smart to allow for pattern matching or cover replacement. You may also be able to use remnants for small cushions. Purchase fabric specifically for outdoor use.

Sewing Tools and Materials Needed

Gather these supplies before starting your outdoor cushion project:

Fabric – Enough fabric yardage for top, bottom and sides
Thread – Outdoor variety like polyester in a color matching fabric
Sewing machine – Standard or heavy duty home sewing machine
Sewing needles – Size 14/90 quilting needles
Scissors – both paper scissors (for patterns) and fabric shears
Straight pins – Ball head pins won’t snag or shift fabric
Rotary cutter, mat and ruler – For perfectly straight cuts
Iron and ironing board
Seam ripper – For mistakes
Measuring tape
Hand sewing needle – For basting, hemming or repairs
Closure hardware – Zippers, velcro, ties, buttons as needed

Having all equipment ready will make sewing the covers go smoothly.

Patterns and Templates for Outdoor Cushions

You have a few options when it comes to patterning your DIY cushion cover:

Use the Original Cover

If the original cover is intact, you can use it as a pattern for the new cover:

Carefully remove the old cover and lay flat.
Smooth out any wrinkles. Pin to cutting surface.
Cut apart at seams and open up to create a large pattern piece.
Trace around edges adding 1-2” ease.
Cut fabric using these pattern pieces.
Mark any closure placement, corners etc. from original cover onto new fabric.

This allows you to replicate the sizing and shape of the original cover. Only drawback is you must sacrifice the old cover.

Make Your Own Pattern

To create a pattern from scratch:

Draft paper pattern pieces using your cushion measurements.
Trace rectangular shapes on paper for top, bottom and sides.
Make side height equal to cushion height + ease. Make top and bottom lengths and widths equal to cushion length/width + ease.
Add 1” around all sides for seam allowances. Add any closure allowances.
Label pieces clearly. Cut out.
Pin paper patterns to fabric. Trace patterns and cut fabric pieces.

Doing the pattern drafting yourself takes more time but lets you customize sizing.

Use a Commercial Pattern

For convenience, you can also use a commercial pattern like Sure Fit’s outdoor cushion cover patterns. They provide printable patterns for box, knife edge, T-cushions and more in multiple sizes. Order a pattern pack matching your cushion size for easy template creation.

Having a tailored pattern is key to well-fitting outdoor cushion covers. Take time to create or trace accurate pattern pieces.

How to Cut Outdoor Cushion Fabric

Once you’ve determined your fabric yardage and created patterns, you’re ready to cut out your cover pieces:

Lay fabric out flat on cutting surface. Smooth any wrinkles.
Pin pattern pieces in place on fabric. If using a directional fabric, be sure pattern pieces all run the proper direction.
Use very sharp fabric scissors or a rotary cutter to cut pieces cleanly and accurately. Don’t skimp on this step! Ragged edges will unravel.
Mark seam allowance lines if desired using fabric marker. This helps guide sewing.
Cut matching pieces for any cushion ties, closures, welting etc. from scrap fabric.
Clip pieces together and store flat until ready to sew.

Cut pieces carefully right the first time. Don’t cut into seam allowances. Take time to do this step properly for best results.

How to Sew Outdoor Cushion Covers

With your fabric cut out, it’s time for the fun part – sewing! Follow these tips:

Prep the Pieces

Lay out all cut pieces and verify they are correct and complete.
With fabric marker, transfer any closure marks from pattern to fabric. Mark center points on panels to align pieces.
Finish seam allowances if recommended by fabric vendor – usually only for very lightweight fabrics.

Sew Side Panels

Sew short ends of side panels together to make a continuous loop using 1⁄2” seam. This will match cushion height.
Finish seams by zigzag stitching, serging or binding edges.
Press seams open.

Attach Side Panel to Bottom

Pin side to bottom panel matching center marks, seam to seam.
Sew together along one long side using a 1⁄2” seam allowance.
Repeat for opposite side.
Finish seams and press open.

Attach Top Panel

Pin top panel to side/bottom unit matching centers and seams.
Sew the final long edge using a 1⁄2” seam to enclose the cover.
Finish seam edges as desired. Press open.

Sew Closures

Once the basic cover is sewn, add any zippers, velcro, ties, buttons or other closures following pattern guides.
Use scrap fabric to make ties and reinforcement patches.
Hand sew buttons. Use zipper foot for invisible zippers.

Refer to your sewing machine manual for specific instructions on sewing various closures. Take it slow on this important step.

Finish Outer Edges

Finish cover exterior by zigzag stitching, serging or binding all outer raw edges. This gives a clean look and prevents unraveling.
On binding, miter corners for best results.

Inspect cover carefully, make any needed alterations and press well before placing on cushion.

How to Add Ties to Outdoor Cushion Covers

Many outdoor cushions have fabric ties to attach the cover to the cushion base. Here are some options:

Corner Ties

Cut 4 fabric strips 2″ wide x 10″ long.
Fold in half lengthwise and press.
Pin 1 tie evenly spaced along each bottom corner.
Topstitch tie in place along both long edges.

Center Ties

Cut 4 fabric strips 2” wide x 18” long
Fold in half and press.
Pin 2 ties centered on bottom panel long sides.
Pin 2 ties centered on bottom panel short sides.
Topstitch all ties in place along both long sides.

Ties help secure the cover on blustery days. Make sure they are tightly secured and reinforced well.

How to Add Zipper Closures to Outdoor Covers

For a smooth look, install invisible zippers:

Invisible Zipper

Use an outdoor-rated invisible zipper at least 2” longer than cover opening.
Install on bottom panel with zipper pull facing out.
Follow invisible zipper insertion instructions for your machine.
Reinforce zipper ends with bar tacks or patches for durability.

Exposed Zipper

Center standard zipper across bottom panel.
Interface fabric behind zipper for stability.
Sew zipper tape to cover opening using zipper foot.

Take time to neatly install closure hardware for a professional finish. Properly installed zippers will last for seasons.

How to Add Velcro to Outdoor Cushion Covers

Velcro offers easy fastening on cushions. Here’s how to apply:

Use outdoor rated Velcro. Ensure “hook” and “loop” sides match up.
Cut Velcro strips slightly longer than cover opening.
Fuse interfacing to fabric behind Velcro.
Align Velcro on underside of opening edges, keeping pieces tight to edge. The fuzzy “loop” piece often goes on the underside.
Sew around all Velcro edges to firmly secure. Consider zigzag or box stitching for extra hold.
Firmly press Velcro in place. Avoid ironing directly on Velcro.

Taking time to properly adhere the Velcro ensures long lasting closure performance.

How to Add Snaps to Outdoor Cushion Covers

For a clean look, use snaps:

Mark evenly spaced snap placements on cover opening edges. Make sure the “ball” and “socket” sides match up.
Make small slits in cover fabric for socket side. Shave down snap nubs if too bulgy.
Use pliers to set snap sockets into fabric slits. Add reinforcement button if desired.
Sew snap studs in place on opposite edge using dense zigzag stitching.
Set snaps together to ensure proper closure. Adjust as needed.

Avoid sewing through snaps themselves to prevent water entry points. Take care to get snaps aligned evenly across opening.

How to Add Grommets to Outdoor Cushion Covers

Grommets allow tie cords to be threaded through covers:

Plastic Grommets

Mark evenly spaced grommet placement on underside of cover bottom. Avoid seam areas.
Cut small slits for grommets using small, sharp scissors.
Insert grommet through fabric slit. Set according to grommet instructions using a rubber mallet.

Fabric Loops

Cut 1.5” wide fabric strips x 3” long.
Fold in half lengthwise and sew into loops.
Hand sew loops to cover underside at evenly spaced intervals.

Reinforce plastic grommets well so they don’t pull out under strain. Fabric loops offer a softer look.

How to Clean Outdoor Cushion Covers

Regular cleaning keeps outdoor cushion covers looking their best:

Brush off debris after use each day if possible.
Spot clean stains and spills promptly with mild soap and water.
For mold/mildew stains, use diluted bleach or white vinegar solution.
Check for holes,wear or damage needing repair during cleanings. Catch issues early!
Wash removable covers occasionally according to fabric guidelines. Air dry only.
Use fabric protectant spray to repel stains and water. Avoid silicone sprays. Consult manufacturer directions. Reapply every few months.
Consider removable covers to wash when needed.

Store cushion covers out of direct sun when not in use to maintain color and fabric integrity. Proper care enhances the lifespan of your custom covers.

Troubleshooting Outdoor Cushion Covers

Face these common issues with DIY outdoor cushion covers:

Cover Does Not Fit Well

Check measurements and adjust pattern to add ease if needed.
Be sure you cut fabric precisely according to pattern guides.
Repin fabric pieces very carefully lining up seams before sewing if fabric shifted.

Closure Does Not Stay Fastened

Reinforce closure area with interfacing for stability.
Opt for heavy duty closure options like stainless grommets or zippers.
Be sure closure hardware is securely installed with reinforced, dense stitching.

Cover Fades Too Quickly

Use only outdoor rated, fade resistant fabrics. Avoid dyes susceptible to UV damage.
Apply fabric protectant spray designed to block UV rays. Reapply per bottle instructions.
Store cushion in covered area when not in use.

Fabric Develops Holes/Tears

Check quality of fabric. Opt for tightly woven outdoor fabrics without loose threads.
Avoid catching or pulling fabric when sewing seams.
Reinforce high stress points like closure openings.
Hand sew repairs immediately before holes spread.

FAQ About Making Outdoor Cushion Covers

Get answers to commonly asked questions about sewing cushion covers:

What is the best fabric for outdoor cushion covers?

Look for fade resistant, weather repellent fabrics like solution-dyed acrylic or olefin. Polyester blends also work well. Avoid natural fibers like cotton.

Should I make a pattern or use the original cover as a template?

Making a new pattern gives you sizing control but takes more time. Using the original cover takes less work but will replicate any fit issues. Choose the option that best suits your sewing skills and project timeline.

How much ease should I add to the cushion measurements?

Add 1-2” ease to the length, width and height. Thicker cushions may need slightly more ease for easy fitting. Too much ease creates a loose cover but too little will make the cover impossible to fit over the cushion.

Should I pre-wash outdoor fabric before sewing?

Most outdoor fabrics are machine washable but don’t require pre-washing. Check your fabric bolt for specific recommendations. Pre-washing is smart if fabric seems prone to excessive shrinkage. Outdoor fabrics should experience minimal shrinkage.

What size seam allowance should I use?

1⁄2” seams are standard for outdoor cushions covers. This provides enough overlap for sturdy stitching without excess bulk. Clip curved seams and finish edges for best results.

How do I get crisp corners on the covers?

Cut fabric precisely on the corners. Clip into the seam allowance near corners for flexible turning. Grade or notch seams together to reduce bulk. Take time pinning corners before sewing for sharp results.

How do I attached ties securely?

Always reinforce fabric ties by folding or encasing raw edges. Topstitch tightly. Avoid sewing tie ends into the cover seam allowance. Instead sew ties into seam darts or box stitch for security.

How often should I wash cushion covers?

Spot clean as needed during the season. Remove covers and machine wash at the end of the season or as needed if heavily soiled. Allow to air dry fully before reusing or storing to prevent mold.

Final Tips for Success Sewing Outdoor Cushion Covers

Select the optimal outdoor fabric for your climate and setting.
Take time to precisely measure cushions before drafting patterns.
Cut fabric pieces carefully following pattern guides.
Mark pieces clearly to avoid mix ups. Keep cushion sets together.
Staystitch seam allowances on especially lightweight or shifty fabrics.
Reinforce closure areas for lasting use.
Serge or bind seams for a professional finish.
High stitch density provides durability for outdoor use.
Use color matching UV treated thread in your sewing machine.
Make covers removable if possible