How to Shape Foam & Pattern Complex Curves for Sewing

In this video tutorial, we’ll show you how to shape a block of foam into the exact curved shape you need. Achieving a precise shape can be difficult, and we’ll show you our best methods for success. Next, we’ll show you how to take that curved piece of foam and pattern it for upholstery and sewing purposes. We’re using an automotive headrest for our demonstration, but these techniques apply to any contoured foam upholstery application.
Intro - 0:00
Cutting Foam to General Size - 0:41
Shaping Foam - 11:39
Marking Foam for Templating - 17:51
Patterning Newly Contoured Foam - 22:05
Transferring Patterns to Fabric & Cutting - 36:37
Sewing Sides to Middle Panel - 41:40
Tack Stitch End Panels - 48:11
Installing Zipper - 54:19
Sewing Final Stitch on End Panels - 59:56
Inserting Foam - 1:04:49
Materials & Tools List - 1:09:29
MATERIAL LIST:
CushionRite™ Premium Antimicrobial Foam (Firm) - SKU: 124236 www.sailrite.c...
Dura-Skrim® Patterning Material 74" - SKU: 103134 www.sailrite.c...
EverSoft™ Indoor/Outdoor Denim 54" Vinyl Fabric - SKU: 122216 www.sailrite.c...
Seamstick 1/4" Basting Tape for Canvas & Upholstery (36 yds.) - SKU: 122065 www.sailrite.c...
Lenzip® #5 Black Continuous Coil Zipper Chain - SKU: 124596 www.sailrite.c...
Lenzip® #5 Black Style A Single Locking Zipper Pull (Coil Chain) - SKU: 124600 www.sailrite.c...
Polyester Fiberfill 15 Denier - Hollow Slick Conjugate - SKU: 104467 www.sailrite.c...
TOOLS LIST:
Clear Acrylic Ruler 6" x 24" - SKU: 102400 www.sailrite.c...
Sailrite® Blade Foam Saw V2 with Carrying Case (110V) - SKU: 121244 www.sailrite.c...
3M™ Super 77™ Spray Adhesive Low VOC 18 oz. - SKU: 636100 www.sailrite.c...
Gingher® Scissors Right Hand Lightweight 8" - SKU: 101017 www.sailrite.c...
Sailrite® Foam Shaper - SKU: 123583 www.sailrite.c...
Scribe-All® Black Marking Pencil for Vinyl - SKU: 121977 www.sailrite.c...
Fabric Edge Pattern Notching Tool - SKU: 124326 www.sailrite.c...
Deluxe 5-1/2" Magnetic Sewing Guide - SKU: 103597 www.sailrite.c...
Sailrite® Ultrafeed® LSZ Walking Foot Sewing Machine (110V) - SKU: 311602 www.sailrite.c...
Fabric Edge Match Pliers - SKU: 123498 www.sailrite.c...
Basic Thread Snips - SKU: 123222 www.sailrite.c...
Sailrite® Ultrafeed® Industrial Sewing Table - SKU: 120934 www.sailrite.c...
Tape Measure 120" - SKU: 102986 www.sailrite.c...

[@peglegtoo]

Incredible detailed video. Answers so many questions. This should have 100k views. Thanks Salrite.

[@SailriteDIY]

I'm glad you think the video deserves 100k views! Maybe we can start a petition to make it go viral?

[@131dyana]

Marvelous work.

[@kmcclarney]

The tip regarding the zipper needing extra allowance in the material just in case is a great tip

[@cmanycrows8400]

This is why I love CZcams generally and Sailrite specifically. This sort of free, inspiring, and quality instruction should be a lesson to every company. I buy their products because of it.

[@SailriteDIY]

That is exactly why we make these free tutorial videos. To help our customers and feed our families. Thanks!!!!

[@urdangerzone]

That was really informative, thank you

[@kima.6611]

This was very well explained, thank you. I love how the company lists the products they are using and how to find them on the website.

[@davestewart9146]

This is a great lesson to use on my boat, there’s nothing left to pattern from plus I want to change the look, thank you Sir 👍😁

[@SailriteDIY]

Glad it was helpful!

[@chucklenz9011]

Boy that patterning material (with the tips) sure makes that job seam easy. Gotta get some.

[@SailriteDIY]

We got it here: www.sailrite.com/Dura-Skrim-2-Patterning-Material-74

[@kentfarmhouse4039]

Love your videos! Taught me a new way to install a zipper-Thanks!

[@samhutson7966]

This is awesome!! It’s very informative! Keep up the great work!!

[@SailriteDIY]

Thanks!!!

[@deltajohnny]

Great video, ezplanations and filming!! 👏👏 When inserting the foam into the cover, it may be useful to place the foam in a plastic bag, to help with the final "massage" to locate it correctly. I'm not a native English speaker, so please ezcuse if I have not used the correct words 😅

[@donaldcheatham]

Love this - thank you!

[@SailriteDIY]

You are so welcome!

[@ddblairco]

thank you

[@lucerojm3]

Good morning, very good morning. Great videos. I'm learning a lot. I would like to know if in leather upholstery it is necessary to reduce the leather to sew it, especially in covers and cushions thank you very much for your videos a greeting from Spain

[@WatzTX]

Nice video. Very informative. Thank you!

[@SailriteDIY]

Glad you enjoyed it!

[@rafaelabad2950]

i use ordinary see through plastic and a push pin its easier and works for me, and also its faster. but if the leather is already present i usually use the leather itself

[@stefcampagna2321]

Very good job !

[@SailriteDIY]

Thank you! Cheers!

[@jafallica]

Wow, not an easy task but looks amazing.

[@SailriteDIY]

Thanks!!!

[@Matt-rx4pm]

Eric, Why didn't you use silk film to help the foam slide in?

[@SailriteDIY]

Yes, that would have been a good idea.

[@1972mdc]

the shaper works incredibly well - i did it outside with a fleece jacket...not sure i'll ever get the bits out of that jacket again :(

[@SailriteDIY]

So, true. The bits of foam gets all over you. Do it outside or in a garage.

[@cyndiamontgomery6524]

I really love your videos, but would ask you to enable the notification icon, so I can receive notifications of new videos.

[@biomechanique6874]

23.45 the word you need is contoured 👍

[@dans_Learning_Curve]

Where did you get the subscribe and ring bell animation? I'd like to use it in my videos.

[@SailriteDIY]

I do not remember, but I might be able to email you the file. Email me at [e-mail]

[@dans_Learning_Curve]

@@SailriteDIY much appreciated!