I finished a cushion with 3 inch foam and 5/32 welt cord. I don't know if the cushion cover is too small because the welt cord does want to lay on the edge. I wrapped the cushion with batting with spray adhesive. Any tips or suggestions?
I generally cut my top and bottom plates the same size as my foam---1 " bigger than finished dimensions. I then cut my border 3 1/2". This places the welt just below the crest created by the batting so you don't feel it when you are sitting. If you want a real square/boxy looking cushion you would have to cut your border 4" and make your panels smaller to put some tension on the foam.