Ottoman

[SteveA]

First time doing a piece of outdoor furniture.  Sunbrella was good - I cut out a square - sent it to them and had the closest match - 1 yard back in three days.  With shipping $ 32.00.  I could have made the sling a little tighter but it was good enough.  The original had a metal rod covered in plastic that I reused.  Sewed the seams and inserted the metal rods - not easy to slide this assembly into the side tracks.  Backed it out - filed the metal openings a little and heavy coat of dry silicone - it took both me and my son to pull it through.  Almost gave up when it slid in like it belonged.  A chair must be a killer compared to this little ottoman.  Sunbrella is nice stuff.  I used clear nylon thread - probably not the best stuff but I have two spools.  Sewing close to the metal rod is the trick.  I can't remember if it was doc or paul who advised grinding the foot for extra tight sewing - it worked great today.

[scott_san_diego]

Usually the side rails that hold the fabric will have screws in them.  You loosen those to make it easier to slide the sewn fabric in place.  Then tighten the screws.

[SteveA]

Scott - this was similar to that style.  There were two separate side rails that I unscrewed from the legs.  After sliding the fabric into those disengaged side rails I screwed the assembly back onto the legs.  If I did it again I would sew the panel smaller.  Even though the stretch was only 1/4 inch on the new fabric I didn't account for wear when I templated the old covering.   I do like that Sunbrella.  They were very helpful over the phone in corporate - couldn't be nicer and I made the order through Sailrite who also provided triple A service. 
SA

[scott_san_diego]

I order  most of my sling material for these types of chairs through Tri vantage.   Yes,  we usually measure the frame width before we take them apart,  then add material for the spline and then deduct about a 1/4".  Then when you screw it all back together the sling will be nice and tight.