STUDIO 103 @Sand Sea and Air Interiors

Upholstery for Yachts, Aircrafts, Home, Hotels and Office

Learn to talk the talk, then walk the walk

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Terri Madden’s January/February 2015 article for Marine Fabricator Magazine.

Browse the PDF here, or read a text version below.

Whether these are your early years as a fabricator or you are a seasoned “salty dog,” we are all walking a road with a unique language and set of skills. It’s fun to say “boating has been in my family for close to 100 years,” yet other than always having a passion for the water, it was not until July 1995 that I moved to San Juan, Puerto Rico with the the opportunity to manage a sail loft and utilize sewing skills fabricating the random cushion requests that came into the shop. 

For newcomers to the MFA and boating, the first step is to learn the language to “talk the talk”. Reach out to fellow fabricators when you have a question or need assistance to “walk the walk”.

Screen Shot 2016-06-29 at 12.21.57 PMFor example, I had read about “scrim foam” in a Marine Fabricator article featuring cushion construction. During a hurricane, I used the down time to call the author, who was happy to discuss the features of “scrim foam”. It can be 1/16” – ¼” thick and it is used as a backing foam under fabrics, leather and vinyl to add padding and shape. It can be cut, glued, stitched and used in multiple layers to achieve a desired thickness or as a final padding layer over firmer foundation layers of foam. Check with your suppliers, as they can also pre-glue foam to vinyl for wall & headliner applications.

Give it a try for a polished seating look, especially when sewing channel sections in boat seat cushions. The rectangular areas of the aft seating in the photo is a good example of scrim foam pre-stitched to the underneath sections of vinyl before the pieces are joined side by side for the center of the cushion.

Then the seat center is stitched to the front knee rollover band and the seat back center is stitched to the top rollover band, followed by the side bands to join cushion fronts and backs. The technique can be utilized on a basic seat cushion with only 2 – 3 top sections until you are more comfortable with your skill level to sew cushions similar to the custom cushions fabricated to fit the aft seating area for this Viking 68’.Screen Shot 2016-06-29 at 12.22.48 PM.pngAs a new member to the MFA, I learned that there are fabricators who specialize in exteriors yet they would not venture to fabricate a cushion; whereas there are fabricators who specialize only in intricate interiors; then there are those that offer expertise in both fields. Everyone is more than willing to share and ‘problem solve’ any situation you may encounter. Numerous vendors attend seminars & workshops; they offer marine materials that have exploded in design and durability as technology has advanced. For example expanded vinyl with two-way stretch is now available with four-way stretch for jet skis and motorcycles as well as ‘cheap and cheerful’ cushion covers that can be wrapped and stapled to a base without stitched side bands as seen on the Pedi cycle cushions. Screen Shot 2016-06-29 at 12.23.06 PMI recall with fascination reading suppliers catalogues like the palm of my hand. A project for a saloon and 2 cabins came in with “free reign” to recover all the cushions – foam with angles was so new, I had no idea which way was up or down. Fortunately time was not a factor and in hindsight the project that took more than 1 month, would now take only a few days. It was a perfect stepping stone “baby-stems” that we’ve all taken- it was exciting and I began to view all the boats in the bay as future opportunities! Know that wherever you are, to look around for hidden possibilities.

It was during a phone call to a supplier that I learned about the MFA and ironically a salesperson from Bainbridge (who is now head of Serge Ferrari, USA) passed by my shop in 1997 and mentioned the importance of attending the MFA National Convention. This was the only familiar name/ face I recognized upon attended my first MFA convention. Yet I went back to PR with a foundation of friendship and direct access to suppliers that I treasure to this day!

After some of my early interior projects, I developed a chart with illustrations of cushion styles after some verbal confusion transpired in an attempt to decipher a customer request for exterior and interior “airplane style” seating for an Italian Riva.

A visual reference cuts to the chase and having the variety of illustrations shown here should be useful in your shop.Screen Shot 2016-06-29 at 12.23.31 PMUntil now, there has only been one project with more complexity than the helm seating encountered on the Riva. The sail loft that I managed offered mostly exterior Sunbrella fabric, clear vinyl and sailcloth.

Honesty with the boat owner was the best policy and somehow he trusted me to complete the job in less than 1 month.

Clearly I had a lot of research to do, as I actually didn’t know the difference between vinyl used for tarps and covers or ‘expanded’ vinyl. Ironically in a recent discussion with a local decorator, she was appreciative to learn that ‘expanded’ vinyl is used for seating cushions; as an expanded vinyl returns to its original shape. I cringe to think that I almost made the mistake not to use an expanded vinyl on the Riva cushions!

The request for “airplane style” seating was totally new and required the skills to make interior sections for this style of cushion. In a future column, I will expand on how I learned to construct a cushion with interior sections to create hi-lo seating. Below are two images for Pilot Seating: the Riva, which was fabricated as a novice, and the Hydra-Sport, which utilized skills (including scrim foam) developed along the path of earning a Master Fabric Craftsman certification.Screen Shot 2016-06-29 at 12.24.05 PMFortunately now there are applications & digital cameras to assist fabricators so that all information is obtained while “in the field”. This avoids extra site visits and your time back in the shop can go to on-line research, ordering materials and commencing fabrication.

Measure twice, cut once is a “motto” learned from a dear friend & it is worth repeating constantly. Also be sure to attend MFA workshops, which provide valuable information on workflow for small, medium and large shops so that your projects can be estimated, fabricated and installed to everyone’s satisfaction. Even one new tip will grow your skills and make becoming a Master Fabric Craftsman one of your next goals!

Perhaps you will be reading this in Oakland California at the 2015 MFA National Convention. If not, make attending a plan for 2016, because the experience will bring to your business an expansion of craftsmanship, camaraderie and proficiency.

Please write or call to let me know any questions concerns you have or would like to know more about in future articles as we welcome in another year of adventure and honing our skills as marine fabricators!



Author: Sand Sea and Air Interiors

Sand Sea and Air Interiors is the foremost creative and cutting-edge textile studio in the Caribbean. We pursue the design and construction of a sophisticated style focused on quality, comfort and durability, and specialize in unique applications, from dramatic seating and shade solutions to tasteful tote bags for tropical environments. – Terri Madden, owner of Sand Sea and Air Interiors (SSA), is a Bachelor of Science in Textile Design from Philadelphia College of Textiles & Science, Philadelphia, PA, and possesses extensive experience and ability in design and fabrication. Nowadays, as an active member of the Marine Fabricators Association (MFA), Madden speaks professionally at national seminars on subjects such as yacht interiors, cushion construction and window treatments. Madden also frequently contributes articles for Marine Fabricator Magazine. – We'd love to hear from you at!

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