Barstool Cushions: From Bland to Bespoke

Do you have barstools like this needing a makeover?

This is a popular basic barstool style that, well, lacks style, not to mention comfort. It’s simple to make cushions to turn these generic seats into bespoke perches. In this week’s post, I’ll show you how as I create a set of custom covers.

To visualize this project, imagine you’re making a shower cap for your barstool seat. You’ll need a sewing machine, upholstery fabric, 1-inch-thick foam, 1/4-inch elastic, and optional piping cord trim. (I haven’t included amounts because it depends on how large your seats are and how many covers you’re making.)

Step One: Measuring & Cutting

You’ll have to do a little math for this step, but I promise it won’t be too difficult. First, measure the diameter and circumference of the barstool seat and draw a circle that size. You can also flip the barstool over and draw around the seat to make your circle. Then add 5/8 of an inch all around for your seam allowance. Center the pattern on your fabric so any print looks the way you want it to on the seat. Then cut out your fabric circle.

For the width of the side panel, measure the thickness of the seat’s wood. Add 1 inch to account for the thickness of the 1-inch foam you’ll be using. Then add 1-1/2 inches more for the elastic hem and 5/8 of an inch for the seam allowance. So, the formula looks like this: width = x” (wood thickness) + 1″ (foam) + 1.5″ (elastic hem) + 5/8″ (seam allowance). Cut a strip of fabric your calculated width and a length equal to the seat circumference plus 1 inch for seaming the ends together.

Okay, the math portion of the exam is over!

Step Two: Optional Trim

If you want decorative trim around the top edge of the seat, you can add piping cord. There are pre-made piping trims available at fabric stores in basic colors. However, custom-made piping is easy to create and makes your project look so much more professional.

For bespoke trim, start with plain cotton filler cord (available at fabric stores and online). I used the 3/16-inch size for this seat cover. Cut a strip of your fabric 2 inches wide and the length of your seat circumference plus an inch for overlap. Fold the fabric (wrong sides together) over the cord as seen here. Sew the fabric together using a zipper foot to snug the needle up against the cord as closely as possible. The excess fabric with the raw edges is the portion you’ll sew into the seam allowance, so don’t trim it away!

Step Three: Cover Assembly

First, the two ends of your side panel need to be attached to make a loop like a belt. Sew them together (right sides facing) using a 1/2-inch seam to form the side panel ring.

Next, with right sides facing, pin together the outer edge of the circle to one edge of the side panel with the raw edge of any piping in between. Think of it as a sandwich of the two fabric pieces with piping (if used) as the filling.

If you’re including the optional piping, make sure the cord part is closer to the center of the circle than the outer edge so it doesn’t end up on the underside of your cover! Where the two ends of the trim meet, tuck one end inside the fabric of the other end. You might need to remove a little of the filler cord to avoid bulkiness. Then fold under the exposed edge of the fabric join so no raw edge will show.

Stitch the cover layers together using a 5/8-inch seam allowance (which should be snug against any piping). When you’re finished, the seat cover should look as shown when it’s turned right side out.

Step Four: The Foam

To add comfy cushioning to your barstool, draw a circle on the 1-inch foam equal to the seat circumference. You can use the actual seat as a pattern to do this. (Ignore my outer line in the picture – mistake!) Cut out your foam circle. An electric carving knife is the best tool to cut foam, but scissors will work on foam this thin.

Step Five: Securing the Cover

You could sew a quick folded hem on the bottom of the “cap” you’ve made and pop it on the seat with the foam now. However, it’s better to affix the cover so it doesn’t shift around when used.

To do so, turn the bottom edge of the fabric under 5/8-inch and sew that fold in place 1/4-inch from the raw edge of the fabric. Leave open a 1-inch gap in this hem to feed your elastic through the channel you’ve just made. Attach a safety pin to one end of your elastic and push it through the “tube” in the hem, using the pin as a way to grip and guide the elastic. When you’ve returned to the start, set the foam on the barstool and place the cover over it. Pull the loose elastic ends, gathering the bottom of the fabric beneath the barstool seat until the cover feels secure. Pin the elastic ends together to mark your desired size.

Remove the cover and sew the two elastic ends together at the length you’ve just determined, cutting off any excess. Tuck the connected elastic tails into the channel and sew shut the gap in the hem you used to insert the elastic. Return the foam and cover to the barstool seat.