Marshel Spring Unit Cushions

[kodydog]

We have a customer who is into natural. She wants us to rebuild the marshal cushion units on her loveseat that are wrapped in cotton. Rose says yes, I say no.

I've never rebuilt a cotton wrapped marshal unit. I cant even imaging how to stuff it without it getting all bunched up.

I took a strong stance and said, this is something I do not want to do. She says she will show me how.

Yes, this is a domestic dispute. Yes we have been through this before. Somebody help me.

[MinUph]

Its not that bad. They are meant to fill with a cushion machine but you can suck them down with a vacuum and fill them that way. It is part of the trade. Rose might win this one buddy. Don't they usually?

[gene]

I hope this has some info that you can use.

https://youtu.be/p0TX3WfOZGI?t=406

I've only done two rebuilds and the suction on my vacuum worked well.

gene

[65Buick]

Buckminster was the first thing to come to mind.
Other thought I had - latex. Natural too.

[sofadoc]

Many of the older sofas were designed for Marshall units, and foam cushions just won't lay right.

I was always apprehensive about doing them. But they always seem to work out way easier than I expected. Like you, I worried about bunching. But for whatever reason, it just doesn't seem to happen. I bring the zipper around the sides, and wrap the whole unit with black bottom to make stuffing easy. I really don't have to suck it down.

However....... You said the customer is way in to natural. Well she won't get it from me. I use a cotton/poly blend.

[65Buick]

I would be interested to know the comfort of that. I am guessing being springs that it is more comfortable than poly foam.

Does anyone know if the compressing tool that Buckminster uses is a custom built piece?

[sofadoc]

Does anyone know if the compressing tool that Buckminster uses is a custom built piece?

It's called a Lochner cushion stuffer. In the old days before foam became the cushion of choice, most all shops had a Lochner. They're great for stuffing cotton wrapped Marshall units, but don't work too well on today's thick foam cores.

I had one back in the 80's. It had worn parts that were no longer in production. When I moved, I sat it out by the curb.

Then last year, I came to work one morning to find one sitting in front of my shop. Someone nearby was clearing out an old building, and thought I might want it. I've used it a few times on spring unit cushions. But since I do 99% foam nowadays, I really can't justify the enormous space it occupies. If you want it, come get it.

[kodydog]

Thanks all this gives me some ideas. Here is the loveseat. We are getting ready to do it Friday.  The cushions are somewhat deformed but I think they can be saved. They feel good to sit on. My biggest concern is they look strained.

https://photos.app.goo.gl/6DfhuwXlQAwK3rfm2

I unstuffed one and found this. Obviously these have been worked on before. Someone may have added extra batting.  Pretty stained and lumpy. And yes the unit is wrapped with dacron.

https://photos.app.goo.gl/gak5da2CXp5uUcWj1

This is as far as I wanted to go for fear I would cause a big rats nest. The marshal unit looks better than expected but of course we're only looking at one side.

https://photos.app.goo.gl/jEdo5F7zPuDHT4xL2

The one reason I am considering salvaging the padding on this cushion is the customer is concerned about toxic off gassing. And even though Dacron is a man made product that off gasses, I think the cushion is old enough to have finished that process. I'm just not sure if its going to be a big lumpy mess.

We are getting ready to do two camel back sofas for her sister who is also concerned about toxic fumes. She is considering latex. I will tell you what Rose found later.

So here is another question. Does the white cotton used in upholstery off gas toxic fumes? Is white cotton 100% cotton or is something mixed in with it? Its bleached, right? I could call my supplier but I doubt he would know.

[sofadoc]

The stuff I use is a cotton/poly blend. I wouldn't even know where to get 100% felted cotton anymore.

[kodydog]

This photo is one of two sofas we are getting ready to do for the sister. She too is into all natural. This all natural stuff sounds like a good idea to me. We try to eat healthy and organic as much as possible. We buy bottled water because the water in High Springs sucks. Rose cooks with coconut oil and we use non toxic soap and tooth past. On the other hand we handle plenty of toxic supplies in our daily work.

We are going round and round trying to find all natural or non toxic products to recover her sofas with.

https://photos.app.goo.gl/0sOToylNv35SBpSA2

We called our foam supplier, Hickory Springs, to find out about 100% natural latex foam. The best they could do is 70% latex and 30% Polyurethane. The salesman said without the poly the cushion will not lay right. They sell latex for mattresses. This means the smallest piece they will sell is 6"X60"X80". They will cut it into smaller pieces but you have to buy the whole thing. Price is $480.

Rose called around and found a place up north who said they have 100% all natural latex foam. Double the price above. But when Rose examined the spec sheet it has chemicals in it also.

These two young ladies inherited a bunch nice of antiques from their grandmother. And apparently some money too because they don't bulk at our prices. At one point Rose had her talked into HR foam, non California laws and no flame retardant. But when we went to pick it all up she said she wanted the latex. So Rose sent her the spec sheet and told her to make a decision. Everything is striped down and ready to send to the refinisher.  I guess you could say it is a good learning experience. I always thought latex was 100% natural rubber. Can you buy anything these days that is non toxic?
 

[kodydog]

The stuff I use is a cotton/poly blend. I wouldn't even know where to get 100% felted cotton anymore.

That looks like what I use.

[sofadoc]

So is the refinisher going to use all organic?

[kodydog]

Good question.

[kodydog]

I hope this has some info that you can use.

https://youtu.be/p0TX3WfOZGI?t=406

Don't know how I missed this. That was cool. I was surprised at how much cotton he used. The end result was awesome.

I didn't realize I'm almost out of cotton. I thought I had some in storage. 4 rolls coming Wednesday.

After watching the video I think I will throw everything out except the marshal unit. All new cotton.

[65Buick]

Kody this is an interesting project. It is difficult to avoid petroleum products, because it is used in everything.

I believe the cotton I get from my supplier is 100%. I kind of doubt it is bleached, there's no reason to. It would be an extra cost. In any case, chlorine escapes into the air very quickly. By the time it reaches you, it would be done.

I have also checked around for latex. I don't believe my local supplier carries it because demand is too low.
In any case, the foam company advertised on this website sometimes carries remnants and extras. They are listed on the website but I would call. Of course, they are in CA where I am.
The foam company I like to use if I have more time, is foamforyou.com. I see that they have latex cushions available, not just mattress size. It is 100% natural. Dunlop is the word you're looking for there. Not 'talalay'.
By the way, sulfur is used to bond the latex, so it can have kind of a residual smell I have found.

Here is the link for that: https://foamforyou.com/latex-chair-cushion.html
It states 'low VOC' . Not all VOCs are bad for people, so I think one would have to dig a bit deeper. But it does list the primary offenders, that are not present.

Good luck, looking forward to seeing what happens here.