Marshel Spring Unit Cushions

[kodydog]

Thanks 65, sorry I've been out of town these last few days.

I went to your link but could not find "Not all VOCs are bad for people" If its not too much trouble I would like more info on this.

[65Buick]

No problem, kody.
As you know, VOC means volatile organic compound (sometimes the word chemical is used.)
For good reason many of us think any 'chemical' is bad. Water is a chemical compound.

So, VOCs is really just stating that the compound is unstable, and releases into the air. Take peppermint oil. It is not toxic to humans and in many cases useful. But when the oil is allowed to react with the air, it splits apart into what we detect as an odor.
Odors are useful to us because we can tell that something is present. So if we look at one component of noxious off-gassing of PU foam, that is formaldehyde. We can smell it and it is definitely not good for humans.

Organic just means that the compound has carbon in it.

There's a lot more to this but some basics.

[kodydog]

Started the cushions today using the video supplied by Gene. 5 layers of cotton on each side seemed excessive but I did it anyway. Rose made a muslin liner and I stuffed the first one. Very happy with the results. Still working on the finished product.

[kodydog]

The love seat is finished and ready for delivery.

5 layers of cotton on the bottom and 5 layers of cotton on the top.
https://photos.app.goo.gl/9hKFUao5b0QtulS53
https://photos.app.goo.gl/ig0T5MMyCpS8wESj2

At this point I was wondering how I was going to get all that into Roses muslin liner. The shrink wrap was an option but Sofas suggestion to just stuff it kept playing in my mind. So I hand sewed the top layer of cotton to the bottom layer of cotton and ended up with this.
https://photos.app.goo.gl/wSd61G4exarQwWE12

Then I stuffed it into the liner and it went in pretty easy.
https://photos.app.goo.gl/D6Uf7PzoAAGLFJUG2

Rose sewed the casings today and I finished it off. Its ready for delivery tomorrow.
https://photos.app.goo.gl/FbiDHpvcvK1B8iuN2

[MinUph]

Nice job Kody, This is when I really miss my machine.

[65Buick]

Looks great Kody. Did you test sit on it?
Thanks for sharing.

[kodydog]

I sat on it and it felt great. I still can't believe all that cotton fit in that cushion. BTW 65, thanks for the off gassing info. I never thought of it that way.

Delivered the love seat this morning and the customer was pleased.
Picked up a large Pottery Barn sofa while we were there. It should be a simple fabric off, fabric on job

The refinisher delivered her sisters sofas yesterday. Painted gloss white lacquer. Rose is ordering the latex now.

Thank you for everyone's helpful advice.

[SteveA]

It doesn't get better than that Kody.  Did you install zippers or sew it closed like in Gene's video ?
SA

[gene]

Great work KodyD. It is interesting how much cotton it takes.

SteveA: That wasn't my video. I just posted it. Thanks for the compliment though. I've got about 20 more years of practice before I'm as good as Buck on authentic antique restoration upholstery. If you're interested, he's got a video on his youtube channel where he upholsters a chair that has a metal frame. Everything needs to be tied to the frame. That's a pain in the wrist.

gene

[kodydog]

It doesn't get better than that Kody.  Did you install zippers or sew it closed like in Gene's video ?
SA

Rose put a zipper on it like the original. The original cushion didn't have a muslin liner. We added one and Rose put a zipper on that too.

[SteveA]

Hey Gene - sorry meant to say "a video Gene posted"  I have watched Bucks videos but I hadn't seen that one.  He is sympathetic to the classical ways and although I like seeing how it was done I can't say that I've tried any of his methods - well maybe one.  I would sandwich the marshall units in foam with a layer of cotton and dacron - those old ways don't seem worth it to me.  I also would use spray glue to sturdy those marshall units from moving and muslin like Kody did to button it up.  I have used bucks technique to tie down horse hair when adding horse hair to an existing job. 
I wonder if those steel cushion machines have been replaced by vacuum bags that shrink the core enough to get it into the casing then they re-inflate?
SA

[SteveA]

Gene back in Jan I had two modern steel frame chairs to do ...the foam was ok but the perilli straps were shot.  I have a heavy duty hand stapler  that I used to attach one strap to another while pulling the opposite end tight.  Then I used hog rings to give the strap connection more strength.  I was on the last strap and while squeezing the hand stapler I ruptured a tendon in my finger.  Dr. said it's trigger finger and will heal 100 % - it's been 4 months and it only feels 50 % better.  Anyway I went on ebay and bought a pneumatic plier stapler for $ 25.00.  an old one but it works great - you only need 40 lbs pressure and the staples are stronger than the hand stapler so no hog rings are necessary.  Didn't get another job for it yet but I'm itching to use it.
SA   

[65Buick]

Steve do you have a photo of this? I can't figure out what you are taking about.

[kodydog]

One manufacture I work for used a long jawed pneumatic stapler to attach the seat front to the spring cover. In all the years I've been recovering furniture I have never seen this method. It was rather odd.

We started the two matching sofas this week. We received the latex for the cushions. I was a bit disappointed they pieced (glued) some together. We could send it back but are too far into it to stop production now. I think it will be all right.

We also ordered 1" latex for the inside backs. I used a layer of cotton under the foam and two layers of cotton on top of the foam. It feels pretty good.
https://photos.app.goo.gl/4GWUKojteBTa3LBr2

[SteveA]

Ian this was a pair of Mid Century chairs - the seats were redone because the straps failed.  We kept the original foam and slip cover since the customer didn't want the expense to change those materials.  The slip cover is dark gray.  I wrapped all the foam with muslin glued on to help give the foam a few more years.  Only the straps on the seat had to be replaced - the stapler in the photo is the one I strained my hand using.  That finger is still messed up.
SA