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Project Details

Fabric 1

Morbern Allante
Producer/Manufacturer: The Miami Corp.
Primary Use: Main Fabric

Fabric 2

Ultrafoam from Albany Foam
Producer:
Primary Use: Foam for Couch Cushions

Please describe the project specifications

The couches in the main salon of this Ocean Yachts sport fishing boat were in need of new foam and recovering. The couches had been made by two different manufacturers and had different thickness of foam and different designs in the cushions themselves. The client wanted to replace all of the foam with the end result that both couches looked the same. Upon removing the large couch, we found that it had been extended at some point and the design of the extension was different from the rest of the couch, which we would have to address to fulfill the client's request. During the disassembly, we also found that some of the seat frames were broken, the jute under the seats had deteriorated, and a family of rodents had once lived inside the couch frames and left considerable biological debris. We rebuilt the seat bottoms using different thicknesses of foam to have a consistent height around the salon, replaced the jute in the seat bottoms and sterilized the couch frames. The foam in the couch backs was also deteriorated, requiring new foam to be cut and shaped to ensure a consistent appearance for both couches, while also providing adequate cushioning to make them comfortable. Once the new foam was cut, we patterned it and new covers were made using Morbern Allante that we laminated to 1/4" sew foam. The end result was a set of beautifully matching couches with perfectly aligned seams and very comfortable cushions. The embroidered throw pillows bring the whole look together and the client absolutely loved the finished product.

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