Can I Put a New Cover Over My Old Sewn-On Cushion?

Many outdoor and budget cushions come with covers that are sewn shut. There's no zipper, so when the fabric fades or tears, you can't simply swap it. A question we get often is whether you can slip a new zippered cover right over the old one. You can, but we don't recommend it. Here's why, and what to do instead.

Quick answer: You can put a new cover over an old sewn-on cover, but it will look overstuffed, roughly twice as puffy as it should, and the zipper will strain. The better fix is to cut the old cover off along its seams, check the foam, and put the foam into a new zippered cover sized to the foam. Keep the old cover pieces if the cushion has an unusual shape: they make the most accurate template. If the foam is flat or crumbling, replace it too.

Why a cover over a cover doesn't work well

A new cover is sewn to fit a cushion of a certain size. When you put it over an old cover, you're adding two layers of fabric, the old seams, any piping, and often a layer of old batting. That extra bulk has to go somewhere.

• It looks overstuffed. The cushion bulges, the edges round off, and it can look much bigger than the cushions around it.
• The zipper strains. A cover that's too tight is hard to close, can buckle along the top, and puts stress on the zipper and seams.
• The old piping shows through. Thick welt cord under the new fabric makes ridges along the edges.
• Moisture gets trapped outdoors. Two layers of fabric hold water longer, and an old cover that's already mildewed stays inside your new one.

If you measured the old cover to order the new one, the problem is worse. The new cover will be the same size as the old cover, with no room for the old cover inside it.

The better way: cut it off and reuse the foam

1. Unpick or cut along a seam. Use a seam ripper or small scissors along one of the long edges. Cut the stitching, not the fabric, if you can.
2. Slide the foam out. Peel the cover away. If the foam is glued or stapled in places, work slowly so you don't tear it.
3. Check the foam. Press it down and let go. If it springs back and isn't crumbling, cracked or badly stained, you can reuse it. If it stays flat, sheds yellow crumbs or smells of mildew, replace it.
4. Measure the foam itself. Measure length, width and thickness edge to edge, with nothing around it. Round to the nearest quarter inch.
5. Order a zippered cover to that size. Our cushion covers are made for foam you already have, and every cover has a zipper so you can remove it for cleaning later.

Keep the old cover if the shape is unusual

This step is easy to miss. If your cushion has rounded corners, a curved back, a T shape, notches or a tapered edge, the old cover is the best template there is.

When you cut it off, open just one seam so the pieces stay together. Lay it flat, and if we need it for an unusual shape, we can ask you to send it to us, or you can trace it onto paper to make a full-size template. Curves are hard to describe with a tape measure, and a template takes the guesswork out. See custom-shaped cushions for how we handle shaped pieces.

Covers only or a complete cushion?

Once the old cover is off, decide whether you need just covers or new foam too.

• Covers only makes sense when the foam is in good shape. Please note that a covers-only order is the cover alone. It doesn't include a foam insert.
• A complete cushion makes sense when the foam is flat, crumbling or mildewed, or when it's the wrong type for where the cushion lives. Regular foam soaks up rain outdoors, so outdoor cushions are better with quick-drying Dry Fast foam.
• Foam only works if you've found a cover you like and just need new foam. See custom-cut foam inserts.

If you're replacing the foam anyway, you don't need to cut the old cover off carefully, unless you want it as a template.

What about tufted or fiber-filled cushions?

Some sewn-on cushions aren't foam at all.

• Tufted cushions (with buttons or stitched dimples) have the cover pulled into the filling. Once you cut the cover off, the filling usually isn't a clean block you can reuse. We don't make tufted cushions, so for these, order a complete replacement in a standard, untufted style.
• Fiber-filled back pillows are stuffed with loose polyester fiber. Loose fiber tends to slump to the bottom over time. If you want a back cushion that keeps its shape, consider replacing the fill with foam. Our Super Soft foam is made for back cushions only.

Measuring mistakes to avoid

• Measuring the old cover with the cover still on when you want a cover for the bare foam. Measure the foam once the old cover is off.
• Measuring to the bulge. Measure flat edge to edge, not around the curve of a puffy cushion.
• Trusting the furniture's listed size. Published sizes often don't match the cushions. Measure what you have.
• Forgetting the shape. If the back of the seat is narrower than the front, measure both. A rectangular cover won't fit tapered or T-shaped foam well.

Our measuring guide has diagrams for every shape. When you're ready, browse our custom cushion covers.

When we're not the right fit

• We make removable zippered covers. If you want a non-removable, sewn-shut cover, we're not the right choice.
• We don't make tufted cushions.
• We don't sell thin foam toppers to add on top of old foam. If the foam is flat, replacing it is the better fix.

Frequently asked questions

Can I put a new cushion cover over the old one?

You can, but it will look overstuffed, roughly twice the size, and the zipper will strain. Cutting off the old cover and reusing the foam gives a much better fit.

How do I remove a sewn-on cushion cover?

Use a seam ripper or small scissors along one long seam, then slide the foam out. Open only one seam if you want to keep the old cover as a template.

Should I measure the old cover or the foam?

The foam, once the old cover is off. Measure edge to edge and round to the nearest quarter inch.

Does a cover-only order include foam?

No. Covers only means just the cover. If your foam needs replacing, order a complete cushion or foam inserts.

My old cushion has an odd shape. How do I order a matching cover?

Keep the old cover in one piece and use it as a template, or trace it onto paper. Rounded corners only need measurements; strong curves need a template.

Is it worth keeping the old foam?

If it springs back and isn't crumbling or mildewed, yes. If it stays flat when you press it, replace it.

Sources

• Questions customers send our care team about replacing sewn-on and non-removable cushion covers, and the cover and foam orders we make.