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How to Make Curved Arms for a Morris Chair

The Morris chair was first produced in England in 1866. It is a type of reclining chair with strong, straight lines. The arms of this chair tend to be wide and flat. Often, those arms are made of solid wood. The Morris chair is still made today in many variations. Older versions of the chair are often tucked away in attic corners. One way to update the arms of the chair is by curving arms with upholstery. This is particularly helpful if the tops of the chair arms are damaged or in poor repair.

Things You'll Need

  • Tape measure
  • Round foam cylinder
  • Serrated knife
  • Scissors
  • Electric carving knife
  • Staple gun
  • Fabric
  • Pins
  • Sewing machine
  • Double welting trim
  • Hot glue gun
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Instructions

    • 1

      Measure the length of the arm and add 3-inches. Measure the widest part of the top of the arm and add 2-inches. Select foam cylinder or oval cylinder as wide as your modified measurement for the top of the arm. Cut two pieces of the foam to that length.

    • 2

      Make a cut halfway through the foam diameter 1 1/2-inches from each end on the same side of the foam. This will be the underside of the foam. Cut a 1-inch wide groove between the two end cuts centered down the length of the foam. Use a serrated knife to cut the foam. Cut the groove through half the thickness of the foam.

    • 3

      Turn the knife toward the side of the foam at the bottom of the groove, keeping the tip of the 1-inch from the side. Cut from one end to the other. Repeat on the other side of the groove. Your cut should be in the shape of an upside-down T. Open the cut sides to make the cross bar of the T 1-inch thick like the groove. Your cuts do not need to be perfect. Turn the foam over and try to fit it over the arm of the chair, so that the foam covers the entire arm. Trim more foam until it fits. Repeat for the second arm.

    • 4

      Staple the foam to the underside of the chair along both the inside and the outside edges of the chair. Contour the inside of the foam where it curves around the seat back cushion. Repeat for both arms.

    • 5

      Measure the length of the foam from the front edge to the back edge. Add 1-inch. Measure the width of the foam and add 2-inches. Cut out two pieces of decorator fabric. Place decor fabric over the front end face of the foam. Cut around the outside of the foam adding 1/2-inch on all sides for seams. Make a second piece for the second arm. Repeat for the back end of the foam. Cut two pieces.

    • 6

      Fold the fabric over the arm in half, with the face sides together, along its length. Sew a double 1-inch seam 1 1/2-inches from the end. A double seam means you sew the seam twice to reinforce it. Repeat for each end. Place the front end face piece against the end of the arm fabric. Pin the fabrics face sides together and sew and 1/2-inch seam. Ease your seam with notches. Pin and sew the back end cover the same way. Turn the cover right side out.

    • 7

      Place the cover over the arm of the chair with the open side to the bottom. Fold the fabric under where the seams end. Staple the fabric to the underside of the chair, keeping the staples tight to the inside wood corner. Repeat on both sides of the arm.

    • 8

      Glue double-welt trim from the back of the arm along the side, wrapping the front, and down the other side, covering the staples. Use a hot glue gun. Repeat for the second curved arm.

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