How to Sew Cushions for a Camper Van

In the last instructables, we shared how to build a table-bench-bed unit. In this instructables, we share how to make the cushions for both the benches and the bed.

Our past steps also include: how to insulate a camper van, how to build the storage platform, and how to finish the walls with cedar paneling.

DISCLAIMER: This is the first van conversion we are doing, so this is certainly a process of trial and error! We tried to describe at every step the reasons why we made the choices we made, so hopefully you can see that we used common sense to design this process. I am an industrial designer and design researcher and my boyfriend is a landscape architect with some knowledge in wood working. I learned how to sew from my mom Louise and my grandma Lucia, since I was a kid. We see this project as an experiment and as a wonderful place to try out some ideas about design, materials and fabrication.

For a short story of how we travel in winter, check out this article on the go-van.com website!

For an overview of the work we did, take a look at our timelapse videos!

Step 1: Materials

For the cushions, we used:

• 10 meters of grey fabric, a mix of 40% cotton and 60% polyester. We used a mix of cotton and polyester to find a balance between a fabric that could be washed easily, that would be comfortable to sit and sleep on, and that would not gather too much moisture (since snow or water might come in the van with us).
• Grey thread
• 10 dark grey zippers
• 7 foam pieces of 4 inches thick, cut to dimensions. We sourced our foam in a local shop in Vancouver and they were able to cut the pieces to the size we needed.

Step 2: Tools

For tools, we used basic sewing tools:

• Sewing machine (borrowed from our friend Belinda who makes lovely leather mittens and bags )
• Fabric scissors
• Seam ripper
• Small ruler and long measuring tape
• Pins
• White pencil to draw on the fabric
• A square
• Iron and ironing board

Step 3: Take Dimensions and Make Sure Everything Fits!

To start, we took the dimensions of the cushions we would need. We had already designed the benches and bed, so we just needed to make sure that cushions would fit on top of that. We separated the cushions into areas that still allowed us to access the storage compartments in the benches. We also had to think about how 2 of our long cushions would serve the dual purpose of back rest in seated position, but also complete the bed space when sleeping. A few math calculations and we were ready to go. Here are our dimensions:

• 1 large cushion for the back section: 68 1/2 x 24 inches
• 4 small cushions for the seats: 23 3/4 x 17 inches
• 2 long cushions for the seat backs: 48 x 17 inches

When we took our dimensions, we made sure to be slightly generous, to make sure that when the cushions were all down into bed mode, there would be no cracks in between them and that they would be quite tight together.

Step 4: Small Cushion First: Measure + Cut

The strategy for each cushion was to cut 2 pieces for the top and bottom of the cushion and then cut one long band that would wrap around all 4 sides and connect the top and bottom pieces.

** Also, it was very important to cut and sew the pieces just a little smaller than the size of the foam so that the fabric was nice and tight on the cushions. This prevented having wrinkles in the fabric once we were done.

Let's start with the small cushions. The dimension of the foam is: 23 3/4 x 17 x 4 inches. This means, I will aim for a cover that is 23 1/4 x 16 1/2 x 3 1/2. I took 1/2 inch off all dimensions.

When thinking about the dimensions to cut, I leave an extra 1/2 inch on each side, to allow for the seam.

The dimensions for cutting are the following:

• 2 pieces of 24 1/4 x 17 1/2
• 1 piece of 59 1/4 x 4 1/2
• 2 pieces of 24 1/4 x 2 3/4 -- > these pieces are for the two sides around the zipper.

Using a long ruler or measuring tape, as well as a square, draw the pattern on the fabric. Then cut with the scissors.

Step 5: Small Cushion: Zipper

The first step for sewing was to sew the zipper onto the side band. We wanted to add a zipper to the covers so that we could remove the covers if necessary to wash them once in a while. The zipper on the small cushions is on the long side. Since the zippers we have were longer than 24 inches, we just left the end side come off the edge for now. The important part is that the zipper's head is at about 1 inch from the edge of the cushion.

Here are the sewing steps:

1. Sew the two thin bands together (the ones that are 2 3/4 inches wide)
2. Open the two pieces and place them flat on an ironing board. Iron the seam flat
3. Install the zipper foot on your sewing machine. This foot is usually the one that allows the needle to be completely at one side of the foot to leave some space for the zipper's teeth.
4. Start by sewing one side of the zipper. Just follow the zipper's teeth, all the way on the length side.
5. Then do sew the other side.
6. Because we didn't want the zippers to go until the end of the side (to prevent from too much pressure on the side seams), we decided to let the zippers start and finish about 1 inch to the edge. To stop the zippers, sew over the zipper's teeth at the two ends. Be careful with the needle and go slowly, especially if you have metal zippers.
7. Use the seam ripper to open the seam where the zipper is.
8. Use scissors carefully to cut the extra part of the zipper at the end.

Step 6: Small Cushion: Sew the Sides

Now, we have one long band to do the sides and one shorter one that has a zipper in it. Sew the pieces together to make one long band. Don't sew the 2 end pieces together quite yet, we will do this at the end once, we have sewed the side pieces to the bottom piece.

Step 7: Small Cushion: Sew the Bottom

Once the side band is ready, I started to sew it onto the bottom piece. I started with the side that has the zipper, because this is the one side that needs to be exactly positioned. I followed along the edge until the corner. At the corner, I pined the needle in, raised the presser foot, turned the fabric 90 degrees, folded the side fabric and pressed the presser foot down again before sewing that line. I did all 4 sides of the cushion.

Once the 4 sides were done, I sewed the last edge on the side of the cushion. I made sure to have a nice 90 degree angle with the bottom to have all sides perpendicular with the bottom.

Step 8: Small Cushion: Sew the Top

The last part to sew for the small cushion was to sew the top. Because here is it important that all the dimensions arrive flush at the end, I pinned each side first. This allowed to make sure I would have just enough fabric when I get at the end (not too much or too little). I did the same process as to sew the bottom part with turning at each corner.

TIP: I had the zipper open to do this, so I could have my hand inside the cushion to work with the fabric!

Step 9: Medium Cushion: Measure + Cut

I used the same strategy as for cutting the small cushions: cut 2 pieces for the top and bottom of the cushion and then cut one long band that would wrap around all 4 sides and connect the top and bottom pieces. One difference here was that I was not able to cut just 1 long band that would go all around, so I split it in 4 sides that I sewed together.

** Again, it was very important to cut and sew the pieces just a little smaller than the size of the foam so that the fabric was nice and tight on the cushions. This prevented having wrinkles in the fabric once we were done.

The dimension of the foam is: 48 x 17 x 4 inches. This means, I will aim for a cover that is 47 1/2 x 16 1/2 x 3 1/2. I took 1/2 inch off all dimensions. When thinking about the dimensions to cut, I leave an extra 1/2 inch on each side, to allow for the seam.

The dimensions for cutting are the following:

• 2 pieces of 48 1/2 x 17 1/2
• 1 piece of 48 1/2 x 4 1/2
• 2 pieces of 48 1/2 x 2 3/4 -- > these pieces are for the two sides around the zipper.
• 2 pieces of 17 1/2 x 4 1/2

Using a long ruler or measuring tape, as well as a square, draw the pattern on the fabric. Then cut with the scissors.

Step 10: Medium Cushion: Zipper

Here, I used the same process as for the small cushions. However, I was not able to find long zippers, so I used two small ones that met in the middle. As for the small cushions, the zippers were a bit long a the ends so I cut them and sewed them to secure them.

Step 11: Medium Cushion: Sew All

Follow the same instructions as with the small cushions. This means starting with sewing the side band bands together (the 3 sides and the side with the zipper). Then I sewed the band to the bottom first, and then adding the top.

Step 12: Large Cushion: Measure + Cut

I used the same strategy as for cutting the medium cushions: cut 2 pieces for the top and bottom of the cushion and then cut one long band that would wrap around all 4 sides and connect the top and bottom pieces. Again, the long side band was actually 4 pieces that I sewed together.

The dimension of the foam is: 68 1/2 x 24 x 4 inches. This means, I will aim for a cover that is 68 x 23 1/2 x 3 1/2. I took 1/2 inch off all dimensions. When thinking about the dimensions to cut, I leave an extra 1/2 inch on each side, to allow for the seam.

The dimensions for cutting are the following:

• 2 pieces of 69 x 24 1/2
• 1 piece of 69 x 4 1/2
• 2 pieces of 69 x 2 3/4 -- > these pieces are for the two sides around the zipper.
• 2 pieces of 24 1/2 x 4 1/2

Using a long ruler or measuring tape, as well as a square, draw the pattern on the fabric. Then cut with the scissors.

Step 13: Large Cushion: Zippers

Follow the same instructions as for the medium cushions, with 2 zippers meeting in the middle. The only difference here, is that the zippers will not need to be cut at the extremities, but rather there will be a short distance between the end of the zipper and the edge of the cushions. This is fine, as long as you have an opening that is large enough to welcome the foam cushion.

Step 14: Large Cushion: Sew All

Follow the same instructions as for the medium cushions.

Step 15: Put the Foam in the Covers!

Last step! Now, we just had to put the foam in the covers. Since the covers are made slightly smaller, this is a bit tricky, but with some patience, it ends up not being too hard. We tried to put the corners in first and then go from there. For the small cushions, I was able to do it alone, but the big ones are a bit harder to manage, so we did it with one person compressing the foam and the other placing the fabric in place.

Just make sure that the seams are at the edges of the foam and there you go!

Step 16: Enjoy!

This is it! Bring the cushions to the van and enjoy them during the day as much as at night!

We have been using the cushions for our trips since December 2014, so it has been 6 months now. We couldn't be happier with the cushions! We found that the material we picked is easy to clean if anything spills on it. Also, in addition to being more comfortable, the cushions also add a layer of insulation for us when sleeping which is much appreciated during the winter time!