Double Tier Cushions - Make those?

[baileyuph]

I had a double tier cushion ottoman, top cushion (3 in.) and lower cushion (6) in.

One zipper and both tiers were filled with foam at those dimesions.

Further, the double tier cushions were integrated into the lower covering that held this double tier situation to the ottoman frame.  It was an integrated system and when it came off the machine it was ready to stuff and staple to the ottoman frame.

These integrated upholstery systems like this are the vogue in so much of the new upholstered pieces.  I can see where it saves finish materials.  Kinda of makes one scratch their head when working working on one or duplicating one.

For example, to work on an integrated upholstery system like this, the system has to be removed from the ottoman frame.

Just wondering how others experience is going with this work?

Doyle

[MinUph]

For example, to work on an integrated upholstery system like this, the system has to be removed from the ottoman frame.

Doyle

Doyle,
  How else would you do an ottoman of any type? Just wondering. I hate these things. Makes me glad to have a seamstress that deals with this stuff.

[baileyuph]

How else to deal with these types, the integrated you mean?

Well, don't integrate the cushion covering system.  Or reduce the integration to the boxing and decking but only build one tier of cushion. 

We have done ottomans by Henredon for over 30 years which were made this but not integrated to the extent of connecting two - tier cushions, one zipper.

At the manufacturing level, one can easily see the motive, it reduces the primary covering yardage and that can get pretty significant when dealing with higher end leather.

Further, the factories will be much more efficient than most small shops would be. 

No, for years, factories have put out cushion top ottomans without sewing the cushion top cover to the lower section of the ottoman.

Back to the double tier, the negative becomes obvious when repairs enters the picture.  Just to change the foam, or one of the cushion foam, like I said the entire integrated system has to be pulled from the ottoman frame.  Same actually if there is a fabric repair.  Remove all the staples, get the upholstery assembly off, then pull the cushion foam for both cushions, do the repair and reassemble every thing you disassembled or took out.

It might be interesting to see these made in a factory. 

The scale of furniture today is larger than years ago, this means a lot of these ottomans especially when associated with sectionals can be almost as big as a small bed and are not of standard geometry. 

Just go through your mind imagining the sequence of sewing events required to build the integrated upholstery system.

Paul, you and your sewing assistant are doing some of this magnitude?

I cannot compete with mass production on these, by the time all staples are removed, foams are removed, and everything is unseamed, and you know the rest required to do the job, I cannot produce something like this close to what new cost.

Anyone else producing this type of custom upholstery and making money at it?

Doyle

[kodydog]

Gotta price those jobs high enough that you rarely get one. And when you do it needs to be worth your while. Some jobs just aren't worth it. You don't want to get the reputation as the guy that will do the hard, money losing jobs. If you do you will spend your days doing only recliners. Not a good proposition.

[Rich]

Sounds like auto upholstery. I've done both auto and furniture, but far more auto and the main difference I saw was that automotive upholstery was made in such a way that just about anyone could install the cover since all the fastenings were sewn in at just the right place. Very little adjusting was necessary. When I got into this business, seat covers were still being made and installed and, unlike the factory, the person doing the cutting and sewing made an open ended slip cover that the installer then folded over at the right length and hog ringed in place. Furniture upholstery has traditionally been this type of pull, regulate the seam and staple operation requiring more skill on the installers end. I guess the furniture mfgrs. are catching on to the idea the auto mfgrs. have used for years. When I went out on my own, (auto trim) I did a lot of insert replacement and learned to duplicate the factory method, so I guess I got used to it. But you're right Doyle, this method does make life harder for the person who repairs it.
Rich