How to Replace Foam on Chairs

Remove the covering from the chair. Remove the tacks, pins and staples carefully, or pull out stitching when required. Don't cut the covering if you want to reuse it after replacing the foam.

Measure the amount of foam you need. Measure the size of the cover, if reusing an old cover, to estimate your foam needs. If you are recovering the chair itself, rather than a removable cushion, you can add a slightly thicker layer of foam to make it more comfortable. Measure the chair if you are not reusing the old cover. Don't measure the old foam because it may have broken down and compressed over time.

Cut the new foam to size from the foam slab. Use an electric carving knife to cut the foam smoothly. If you don't want to cut your own foam, once you have the measurements you can have an upholstery shop cut a cushion to fit your chair's measurements.

Wrap the cushion in the batting, or affix a layer of batting on the top of the cushion with staples or glue, or by hand-stitching it in place.

Place the foam slab back on the chair, or stuff it back into the cover that goes on it if it is a free cushion.

Smooth all the wrinkles out of the fabric over the cushion. Ensure that you have the fabric pulled tight, and that there are no puckers or winkles, before you start fastening it in place.

Sew the cover back on to the cushion or fasten the fabric back on to the chair with the foam in place. Use the same method for refastening fabric that was used in the chair's initial construction, whether tacks or staples. Do this whether using the original fabric after only replacing the foam, or if you've made a new covering for the chair, as well.