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01-19-2022, 10:01 PM
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#1
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Veteran Member
City: Enfield, CT
Vessel Model: 1982 Albin 40 DC
Join Date: Nov 2021
Posts: 27
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Settee back cushion build
Hey guys- for whatever reason, my 1982 Albin 40 DC did not come with the back cushions for the settee and I want to build them myself. What I need help with is how to bend the 1/2” plywood for the corner piece. I don’t want a hard 90° corner but one with the radii. I had two thoughts:
A.) rip multiple cuts with a table saw through to the last layer of ply, soak wood in water, bend then epoxy in the cuts so it keeps it’s form.
Or
B.) rip strips of the ply on angle to form the bend. Say 6 strips at 15°. Then glue the strips together to and sand the edges for a smooth curve.
Below I have attach a picture of the settee. Any tips or ideas would be appreciated.
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01-19-2022, 10:06 PM
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#2
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Guru
City: Inside Passage Summer/Columbia River Winter
Vessel Name: Alaskan Sea-Duction
Vessel Model: 1988 M/Y Camargue YachtFisher
Join Date: Jul 2012
Posts: 7,530
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Quote:
Originally Posted by SeaBoy
Hey guys- for whatever reason, my 1982 Albin 40 DC did not come with the back cushions for the settee and I want to build them myself. What I need help with is how to bend the 1/2” plywood for the corner piece. I don’t want a hard 90° corner but one with the radii. I had two thoughts:
A.) rip multiple cuts with a table saw through to the last layer of ply, soak wood in water, bend then epoxy in the cuts so it keeps it’s form.
Or
B.) rip strips of the ply on angle to form the bend. Say 6 strips at 15°. Then glue the strips together to and sand the edges for a smooth curve.
Below I have attach a picture of the settee. Any tips or ideas would be appreciated.
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Why not just get cushions? You know Admials love pillows.
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01-20-2022, 01:06 AM
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#3
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Guru
City: Gig Harbor, WA
Vessel Name: MoonShadow
Vessel Model: Wendon Skylounge 72'
Join Date: Oct 2012
Posts: 569
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Quote:
Originally Posted by SeaBoy
Hey guys- for whatever reason, my 1982 Albin 40 DC did not come with the back cushions for the settee and I want to build them myself. What I need help with is how to bend the 1/2” plywood for the corner piece. I don’t want a hard 90° corner but one with the radii. I had two thoughts:
A.) rip multiple cuts with a table saw through to the last layer of ply, soak wood in water, bend then epoxy in the cuts so it keeps it’s form.
Or
B.) rip strips of the ply on angle to form the bend. Say 6 strips at 15°. Then glue the strips together to and sand the edges for a smooth curve.
Below I have attach a picture of the settee. Any tips or ideas would be appreciated.
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I am not certain, but I think that my corner cushions in a banquette have no solid back, just the foam. I will check later this week when I'm on the boat and revert.
~A
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01-20-2022, 01:22 AM
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#4
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Guru
City: Gulf Islands, BC Canada
Vessel Name: Soo Valley
Vessel Model: Grand Banks 36
Join Date: Jul 2019
Posts: 2,734
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A thought.
Use 1/8 veneer X 4 to get 1/2 inch. Build a frame into the corner for backing to bend the 1/8 material past the point where later you will later cut it. Apply glue and lay the next 1/8 and so on. oversize so you can trim to suit.
__________________
SteveK AKA Soo Valley
You only need one working engine. That is why I have two.
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01-20-2022, 06:45 AM
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#5
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Veteran Member
City: Enfield, CT
Vessel Model: 1982 Albin 40 DC
Join Date: Nov 2021
Posts: 27
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Quote:
Originally Posted by AlanT
I am not certain, but I think that my corner cushions in a banquette have no solid back, just the foam. I will check later this week when I'm on the boat and revert.
~A
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Awesome. Thanks AlanT
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01-20-2022, 06:47 AM
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#6
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Veteran Member
City: Enfield, CT
Vessel Model: 1982 Albin 40 DC
Join Date: Nov 2021
Posts: 27
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Quote:
Originally Posted by Soo-Valley
A thought.
Use 1/8 veneer X 4 to get 1/2 inch. Build a frame into the corner for backing to bend the 1/8 material past the point where later you will later cut it. Apply glue and lay the next 1/8 and so on. oversize so you can trim to suit.
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Also a good idea
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01-20-2022, 07:53 AM
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#7
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TF Site Team
City: Seneca Lake NY
Vessel Name: Bacchus
Vessel Model: MS 34 HT Trawler
Join Date: Nov 2014
Posts: 6,315
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Quote:
Originally Posted by AlanT
I am not certain, but I think that my corner cushions in a banquette have no solid back, just the foam. I will check later this week when I'm on the boat and revert.
~A
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Quote:
Originally Posted by Soo-Valley
A thought.
Use 1/8 veneer X 4 to get 1/2 inch. Build a frame into the corner for backing to bend the 1/8 material past the point where later you will later cut it. Apply glue and lay the next 1/8 and so on. oversize so you can trim to suit.
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These were my initial thoughts.
Regardless of which you choose its best to cut the foam about a 1/2" oversize around all sides compared to what you'd like as finished dimensions. Make the cover the finished size desired and "stuff" the foam in to fill the shape w/o any puckers.
If stuffing is difficult use of a very light wt plastic bag (dry cleaner bag) will help and can be left in place or pulled out after providing opening left toward the far end from the covering opening.
Good luck & let us know how it turns out.
__________________
Don
2008 MS 34 HT Trawler
"Bacchus"
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01-20-2022, 11:06 AM
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#8
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TF Site Team
City: Saltspring Island
Vessel Name: Retreat
Vessel Model: C&L 44
Join Date: Nov 2007
Posts: 4,976
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Quote:
Originally Posted by Soo-Valley
A thought.
Use 1/8 veneer X 4 to get 1/2 inch. Build a frame into the corner for backing to bend the 1/8 material past the point where later you will later cut it. Apply glue and lay the next 1/8 and so on. oversize so you can trim to suit.
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All but the final layer can be construction grade plywood, "door skin", the last, fine teak or other veneer to suit.
__________________
Keith
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01-20-2022, 07:20 PM
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#9
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Senior Member
City: Windmill Harbour, Hilton Head Island, SC
Vessel Name: River Girl
Vessel Model: 2004 DeFever 49 RPH
Join Date: Sep 2016
Posts: 385
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why do you need plywood? most corner back cushions are simply a stiff foam (backing) with softer foam on the seat side if that's your preference.
__________________
Jeremy
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01-20-2022, 08:01 PM
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#10
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TF Site Team
City: Saltspring Island
Vessel Name: Retreat
Vessel Model: C&L 44
Join Date: Nov 2007
Posts: 4,976
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Quote:
Originally Posted by Flatswing
why do you need plywood? most corner back cushions are simply a stiff foam (backing) with softer foam on the seat side if that's your preference.
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After another look at the original post, I see he has the teak plywood in place to give shape to whatever cushions are added. The rail above curves around the corner, so the plywood back section below must curve around as well. The OP must be asking only about building the cushions for the corner. His question suggests that he will use plywood inside the cushion to get the curve.
My boat has a similar settee, with a curved corner. Our upholstery has been replaced twice. Building the corner cushion was indeed a challenge. It was accomplished by sewing a curve in the edge pieces of fabric and bending a flat piece of 4" foam into the bent cushion after it was sewn, where the zipper was in the bottom edge. It works. You just need to get the dimensions figured out first.
Measure twice, then cut.
__________________
Keith
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01-20-2022, 09:26 PM
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#11
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Senior Member
City: Kenmore
Vessel Name: Snapdragon
Vessel Model: Custom 56' Skookum trawler
Join Date: Sep 2016
Posts: 241
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This is probably the minority opinion but I will put it out there. I do not understand draw of rounded back corners in boat L shaped benches. The best thing about these benches is that you can lounge around on them in the evening with your back in the corner of the bench, and your legs splayed out. If there is a weird round corner it messes everything up. My advice is to take this opportunity to modify the wood bench back and make it square, then sew square cushions to go with it. If your wood working isn't the best, it won't really matter since it will be hidden behind the cushion. If you do decide to keep the round corner, I would make the normal cushions on either side of it, then take them to a professional, and have them build the round cushion to match the ones you made. I think it is going to be ver hard to make a round cushion that look good.
I recently sewed new cushions for my new boat. My benches were framed square, but there was a rounded cushion in the corner, with a square back. When I made new cushions I changed it to a square corner. It doesn't look quite as custom, but it is way more comfortable than the original set up. It was also way easier to sew.
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01-22-2022, 03:36 PM
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#12
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Veteran Member
City: Enfield, CT
Vessel Model: 1982 Albin 40 DC
Join Date: Nov 2021
Posts: 27
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Quote:
Originally Posted by Snapdragon III
This is probably the minority opinion but I will put it out there. I do not understand draw of rounded back corners in boat L shaped benches. The best thing about these benches is that you can lounge around on them in the evening with your back in the corner of the bench, and your legs splayed out. If there is a weird round corner it messes everything up. My advice is to take this opportunity to modify the wood bench back and make it square, then sew square cushions to go with it. If your wood working isn't the best, it won't really matter since it will be hidden behind the cushion. If you do decide to keep the round corner, I would make the normal cushions on either side of it, then take them to a professional, and have them build the round cushion to match the ones you made. I think it is going to be ver hard to make a round cushion that look good.
I recently sewed new cushions for my new boat. My benches were framed square, but there was a rounded cushion in the corner, with a square back. When I made new cushions I changed it to a square corner. It doesn't look quite as custom, but it is way more comfortable than the original set up. It was also way easier to sew.
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Dude…. I love your settee cushions. That’s a great idea
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01-22-2022, 07:04 PM
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#13
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Senior Member
City: Carefree, AZ and Ft. Myers Beach, FL
Vessel Name: Sea-N-Stars
Vessel Model: 1990 49' Albin
Join Date: May 2018
Posts: 299
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Quote:
Originally Posted by Snapdragon III
This is probably the minority opinion but I will put it out there. I do not understand draw of rounded back corners in boat L shaped benches. The best thing about these benches is that you can lounge around on them in the evening with your back in the corner of the bench, and your legs splayed out. If there is a weird round corner it messes everything up.
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 I could not agree more. It was my first thought when I saw this thread.
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01-23-2022, 10:28 AM
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#14
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Veteran Member
City: Enfield, CT
Vessel Model: 1982 Albin 40 DC
Join Date: Nov 2021
Posts: 27
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Quote:
Originally Posted by Snapdragon III
This is probably the minority opinion but I will put it out there. I do not understand draw of rounded back corners in boat L shaped benches. The best thing about these benches is that you can lounge around on them in the evening with your back in the corner of the bench, and your legs splayed out. If there is a weird round corner it messes everything up. My advice is to take this opportunity to modify the wood bench back and make it square, then sew square cushions to go with it. If your wood working isn't the best, it won't really matter since it will be hidden behind the cushion. If you do decide to keep the round corner, I would make the normal cushions on either side of it, then take them to a professional, and have them build the round cushion to match the ones you made. I think it is going to be ver hard to make a round cushion that look good.
I recently sewed new cushions for my new boat. My benches were framed square, but there was a rounded cushion in the corner, with a square back. When I made new cushions I changed it to a square corner. It doesn't look quite as custom, but it is way more comfortable than the original set up. It was also way easier to sew.
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Snapdragon III- can you tell me how you made your cushions? i.e. fabric, foam, material
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