Why do we need to invest in truly exceptional sofa cushions? Well: you’ve likely spent countless hours converting your van into your palace on wheels, designing it to cater to your every whim and fancy. It would be a downright injustice to furnish it with subpar cushions that offer the support of a damp sponge. Your campervan deserves better, and so do you.
A high-quality cushion not only enhances the look and appeal of your van, but it also ensures that you and your fellow travellers can lounge in comfort, free from the aches and pains that living in a van can induce.
Let’s not forget that in a campervan, space is a valuable commodity, and multi-functional furniture becomes a necessity, so a good sofa cushion can easily transform into a cosy bed for weary travellers when the sun sets on another day of adventure.
Let’s delve deeper into the qualities we seek in our campervan cushions:
Comfort for sitting and sleeping: The perfect cushion is a versatile one, capable of supporting you during leisurely lounging sessions and providing respite after a day of exploration. The ideal filling should strike a harmonious balance between firmness and pliability.
Lightweight for ease of handling: In the ever-evolving world of campervan living, adaptability is key. Opting for a lightweight filling ensures your cushions can be effortlessly moved or rearranged, granting you the freedom to transform your space with ease.
Simplicity in cutting: Crafting your own cushions is an endeavour that requires precision and patience. Choosing a filling that is easy to cut and shape not only streamlines the process but also minimises the risk of errors and wasted materials.
Affordability: As the wise adage goes, “You get what you pay for”. Cushions end up being unexpectedly expensive, so it’s going to be important to think about how much of your budget you are happy to throw at this, and where compromises might have to be made elsewhere.
With these factors as our guiding principles, we champion the foam mattress as the material of choice for your DIY campervan cushions. Something like a 5 – 6 inch high-density foam mattress will withstand the rigours of constant use without compromising on comfort.
To take it even further, a strategic stacking of 2-3 inch high-density foam on the bottom and 2-3 inch medium-density foam on top really delivers. This approach prevents premature sagging or caving, maintaining perfect cushion integrity.
If you’d like, at this point, it’s smart to take a moment to test the waters. Gather samples of the foam, if your supplier will allow, and do some sitting. Cushions are expensive and we want to get them right.
And finally, a word of caution: resist the temptation to overstuff your cushions. In the realm of van life, space is king, and every inch counts. If you can live with an inch less cushion, do it.
Considerations on Cushion Covers
The outer material of your cushions, or the cushion covers, plays an oddly significant role in the overall experience of your van life. Here are some key aspects to consider when selecting the cushion cover fabric:
Durability:
When it comes to cushion covers, durability should be a top priority, particularly if you have children, pets, or plan on renting your campervan. Opt for upholstery fabrics that provide stain and tear resistance, as well as UV and moisture resistance to ensure your cushions can withstand daily wear and tear. Believe it or not, the sun will really stain your cushions! If you can, look for a double rub count over 50,000 or GSM of over 250.
A quick note on GSM: GSM stands for “grams per square metre” which is a measurement of the fabric’s weight and density. In the context of campervan cushions, GSM can be an indicator of the fabric’s durability, thickness, and overall quality.
A higher GSM means a heavier and denser fabric, which is generally more durable and long-lasting. Fabrics with a higher GSM are also more likely to provide better insulation and cushioning, making them more comfortable for sitting (and even sleeping) on.
Low GSM: A fabric with a low GSM typically ranges from 30 to 150 GSM. These fabrics are lightweight, thin, and used for T-shirts and bed linens. Low GSM fabrics are more suitable for warm climates and situations where breathability is desired.
High GSM: A fabric with a high GSM typically ranges from 250 to 500 GSM, or higher. These fabrics are heavyweight, dense, more durable and longer-lasting. Examples of high GSM fabrics include upholstery fabrics, heavy bed linens, and thick clothing like sweatshirts or jackets. High GSM fabrics are more suitable for cold climates and situations where insulation and durability are required.
For campervan cushions, you may want to choose a fabric with a moderate to high GSM to ensure durability, comfort, and insulation.
Comfort:
Choosing the wrong fabric can lead to discomfort or itchiness which will significantly impact your quality of life. Think about how the material will feel in various conditions, such as extreme heat or cold, and consider whether it’s suitable for lounging in shorts or ‘pants’. We chase the sun in our van, and live in shorts and bikinis, so a softer material was important.
Colours:
As your campervan will be exposed to mud, dust, and other elements, selecting a forgiving fabric colour is crucial. Consider darker colours or patterns that can conceal dirt more easily. If you prefer a crisp, airy look, choose a stark white fabric that can be bleached without looking patchy, especially if you have pets.
Types of Fabrics
Polyester:
Polyester is material I guarantee you’ve heard of, it’s used all over in upholstery. For good reason too. It is resistant to abrasion, UV radiation, and mildew.. All good things for a campervan cushion. Polyester fabrics come in various colours, textures, and patterns, so tick in that box too. This material is generally affordable but it’s not as strong as some of the other materials here.
Canvas:
Canvas is a heavyweight, tightly woven fabric that is known for its durability and strength, so it’s ideal for wear and tear of daily use. Like polyester, it’s available in various colours and patterns, and some canvas fabrics are treated with a water-resistant coating for added protection against moisture. It’s not known as the most soft nor comfortable material though.
Sunbrella:
Sunbrella is a high-quality, acrylic-based fabric known for its resistance to fading, mildew, and water. It is specifically designed for outdoor use, making it an excellent choice for campervan cushions. Sunbrella fabrics come in a wide range of colours and patterns and can be machine washed for easy maintenance. While not cheap, Sunbrella is everything we are looking for in a campervan cushion.
Causeway:
Causeway fabrics are marine-grade, budget-friendly, and acrylic-topped. They come with a 3-year warranty, offering a balance between cost and durability. These fabrics typically have a good double rub score, making them a suitable option for campervan cushions.
Sileather:
Sileather is a marine-grade, ethically-produced synthetic leather that offers the appearance and feel of leather while being more eco-friendly. It is durable, stain-resistant, and easy to clean. Sileather typically has a good double rub score, but it comes in at the expensive end of the list.
Vinyl:
Vinyl is a synthetic material that is both durable and easy to clean. It is water-resistant and can be easily wiped down, however, vinyl is not as breathable or comfortable as other fabric options and its environmental impact may be a concern for some. Also, it’s likely to get a bit ‘clammy’ in the heat.
Leather:
Leather is a luxurious, durable, and stain-resistant choice for campervan cushions. It can be cold in the winter and sweaty in the summer, but its durability is undeniable. Leather typically has a high double rub score, and is expensive, which is why you won’t see it in many vans.
Midweight denim:
Midweight denim is easy to work with, affordable, durable, and easy to clean. It is a suitable choice for campervan cushions, though it may not last as long as some other options on this list. Denim’s double rub score can vary, but it is generally considered a budget-friendly choice.
Cotton:
Cotton is a natural, soft, and breathable fabric that is commonly used for upholstery. We all know about cotton. It’s comfortable and cosy and comes in all the colours, patterns, and textures, you could ask for.
That being said, it is essential to note that cotton is generally less durable and resistant to stains, moisture, and UV radiation compared to most of the other fabric options. To improve its durability and resistance to wear and tear, you can opt for a cotton blend or a fabric treated with a protective coating.
How to cut your foam to size
Step 1: Gather materials and tools
You will need the following:
- Foam mattress (a combination of hard density foam for the bottom and medium density foam for the top, if desired)
- Electric carving knife (highly recommended for clean, precise cuts)
- Serrated knife or box cutter (optional, but not recommended for the best results)
- Marker
- Ruler or measuring tape
- Straight edge (optional, but helpful for guiding your cuts)
Step 2: Measure and mark the foam
Using a ruler or measuring tape, measure the dimensions of each cushion piece and mark them on the foam with your marker. Be precise with your measurements to ensure a proper fit. Use a straightedge to draw the cut lines, making sure they are straight and even.
Step 3: Prepare your cutting area
Find a flat, stable surface to work on, and make sure you have enough space to manoeuvre the foam and the electric carving knife comfortably.
Step 4: Cut the foam
Before you start cutting, make sure your electric carving knife blade is pointed straight down to ensure a 90-degree angle. If you’re using a serrated knife or box cutter, the same principle applies. However, using an electric carving knife is highly recommended for cleaner, more accurate cuts.
Carefully follow the marked cut lines, going slow and steady to maintain accuracy. Remember to keep the blade perpendicular to the foam surface to achieve clean 90-degree angle cuts.
(Optional) Step 5: Glue the foam layers together
If you’re using a combination of hard density foam for the bottom and medium density foam for the top, you’ll need to glue the two layers together. To do this, follow these steps:
Align the foam layers so that they are flush with one another.
Use a spray adhesive designed for foam, and apply it evenly to the surface of the hard density foam where it will make contact with the medium density foam.
Press the two foam layers together, ensuring that they are properly aligned.
Allow the adhesive to cure according to the manufacturer’s instructions before proceeding with the cushion construction.
How to make your Cushion Covers
Full disclosure, this is what we understand is the process for doing cushions covers, but it is not what we did. We paid a professional. It’s not a good idea to DIY this if you have not done it before. And if you have done this kind of thing before, you already know this. Just in case, for those interested, here’s the general flow:
Step 1: Gather materials and tools
You will need the following items:
- Fabric of your choice (Sunbrella, polyester, canvas, vinyl, leather, etc.)
- Sewing machine
- Thread that matches your fabric
- Fabric scissors
- Pins
- Measuring tape or ruler
- Marker or fabric chalk
- Zipper or Velcro (optional, for removable covers)
Step 2: Measure and cut the fabric
Measure the dimensions of your foam cushion, adding 1 inch (2.5 cm) to each dimension for seam allowances. Using a ruler or measuring tape, mark these dimensions on your fabric with a marker or fabric chalk. Be precise with your measurements to ensure a proper fit.
Cut the fabric pieces for the top and bottom of the cushion cover, as well as any necessary side pieces if you’re working with a box cushion. Remember to cut an extra set of side pieces if you’re adding a zipper or Velcro closure.
Step 3: Pin the fabric
Pin the fabric pieces together, with the right sides facing each other. If you’re using a zipper or Velcro, make sure to position them correctly between the side pieces.
Step 4: Sew the fabric Pieces Together
Using a sewing machine, sew the fabric pieces together along the marked seam allowances. Start with the side pieces, attaching them to the top piece of the cushion cover. Then, attach the bottom piece to the side pieces. If you’re using a zipper or Velcro, sew them in place as you attach the side pieces.
Step 5: Trim and Finish Seams
Trim any excess fabric from the seam allowances, and finish the raw edges with a zigzag stitch or a serger to prevent fraying.
Step 6: Turn the Cushion Cover Right Side Out
Turn the cushion cover right side out, carefully pushing out the corners.
Step 7: Insert the Foam Cushion
If you’re using a zipper or Velcro closure, open it and insert the foam cushion into the cover. Make sure the foam is positioned correctly and fits snugly within the cover. Close the zipper or Velcro to secure the cushion inside the cover.
If you’ve sewn a closed cushion cover without a zipper or Velcro, carefully insert the foam through the last open seam, then hand-sew the seam closed using a ladder stitch.
What we did
We bought our van with a foam mattress already in it. We didn’t want to sleep on that one, because it wasn’t up to our standards (we value sleep, alot) but it was a nice piece of foam and we thought we could re-use it. We don’t know for sure, because we didn’t buy it, but we think it’s a medium to hard density. It’s 12cm deep.
To re-use it, we removed the original covers, additional stitching and any pins and in doing so got rid of a gross mouldy patch on the outer cover.
Then we measured, measured and re-measured our sofa area. It’s important to measure after building, and not rely on the original drawings, as a few unanticipated cm’s here and there can creep into the build that didn’t exist on your original plan.
We have a very big 2.4m long L sofa in our van so even a small error can lead to a 10mm difference.
Based on the measurements we drew pictures on paper of the sofa layout and aligned the individual cushions up with our under sofa cupboards.
Labelled our new areas on the design A,B,C,D and 1,2,3,4 for the back rests. Interestingly, that is now what we call each of our cupboards. If one of us says something is in B, we know exactly where to look. Funny how little things stay with you.
Used considerable brain power to work out how to use all of the foam efficiently and effectively to ensure we used all of the mattress shape to make the cushions.
Next, we used black marker pen and a ruler to draw on the foam where we will need to cut
We also drew with the marker pen the letter of the cushion so that we knew which was which once cut.
Got the bread knife out and cut along the lines that we drew. Importantly, we did not use an electric one. First of all, we couldn’t get to my nans to pick up hers (because I think only nan’s have these nowadays.. right?) and we were working outside, in a car park at the time, with no way of powering it.
It was pretty easy to cut, but I can see how it would be really easy to get it wrong if you aren’t concentrating. The hardest bit is keeping the thing completely flat whilst getting the knife all the way through. If you don’t cut it cleanly all the way through in one cut, you will almost definitely end up with bumpy bits at the bottom of the cut, where you go through with the knife for a second time.
It is very hard to rectify this if you get it. Pulling on little bits and trying to cut jagged edges with a stanley knife is the first thing you will try and do and it does not work.
Thinking about it, probably best to practise on some foam before jumping into the major cuts. Or, buy the foam pre-cut. Much easier.
For the material, we visited a lot of local material shops. The general vibe was cotton would be fine. Nobody in Cornwall had any fancy marine grade materials.
We ended up ordering one online which was a gamble. It’s a dark green Cotton Canvas, (Materials: Primary fibre: Cotton; Primary fabric: Canvas) at 250GSM. That’s an OK thickness whilst being very soft and comfortable. The cost was £72.
It arrived and we liked it.
I can tell you after 6 months, the sun has heavily stained the cushions by the door, but you can only see it when you take them all apart. Except for that, the fabric has performed fantastically.
We found a local seamstress and gave her the material along with the cushions and asked her to cover them all to include a zip. This was a very local deal, a retired lady who only does jobs for friends and family. She charged us £120, which is a great price. You need to hunt out people like this if you can.
Collected them 2 weeks later. Voila, we have a sofa!
Total price, £192.
I was amazed at how much this costs, considering we didn’t even buy the foam. But it’s money well spent. The sofa is incredibly comfortable and it’s an amazing comfort to have in your van.