STUDIO 103 @Sand Sea and Air Interiors

Upholstery for Yachts, Aircrafts, Home, Hotels and Office


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Seating solutions for reclining, storage and temperature control

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Terri Madden’s March/April 2017 article for Marine Fabricator Magazine.

When a customer requests an unusual type of seating for a boat, it’s a fabrication opportunity to begin a comfortable dialogue with that client. Instead of hesitantly saying, “I will try to do my best,” turn your response into, “I am here to help you.”

That customer may have already heard a reluctant fabricator say, “That’s not possible,” or “That’s going to cost a lot of money.” The open-minded fabricator will thoughtfully listen and ask questions as the customer describes his or her vision. The goal is to cultivate a constructive dialogue that will help a customer understand the value of the fabricator’s time, effort and skills. What’s more, creating an especially challenging seating project may become an award-winner that ultimately showcases a fabricator’s considerable skill and experience.

Customers are often looking for a wow factor in their new marine cushions and seating. At the same time, they usually have budget constraints and want the work completed as soon as possible. To balance these demands, fabricators need to help clients understand the give and take of turning unusual requests into reality.   

When an usually project is requested, here are ideas for preparing for your first meeting with the client:

  • Designate a day to review his or her request so you have sufficient time to explore solutions that will suit the project.
  • Consider whether this project will take away or add to your core business.
  • Review measurements and gather photos of similar projects.
  • Develop sketches and rough drafts for the client.
  • Research the type of materials required, including quantities, costs and availability.
  • Compare the customer’s budget to your rough estimate for materials and labor.
  • Designate your prototype fee in your estimate; this will be different than a quantity fee and re-orders on certain items.

Adjustable chaise seating

Consider what new projects you have seen in the past year. I find it inspiring to view fellow fabricators’ projects that, to my knowledge, had not previously existed in the marine market but are now are frequently seen on pleasure crafts around the world.

Adjustable reclining chaise seating has been in the furniture industry for years, yet only recently have a few fabricators sourced hardware and materials to transition this idea to the marine market. Now this comfortable solution is a reality for marine customers.

In the past, super yachts often incorporated flat cushions into a recessed area on the bow of the boat. Typically these “day bed” cushions have had elevated headrests integrated into the body of a cushion, providing only a few inches of elevation. However, fabricators like David Elliott, owner of David’s Custom Trimmers in Australia, have recently utilized a 25 mm Kingboard as a custom base with a stainless ratchet-hinge. The hardware is available from Taco Marine. This fusion has provided a durable and comfortable solution for guests to sit side-by-side with one person relaxing in an upright position while another person reclines.

Since the completion and installation of this project, Elliott has been sourcing additional prototypes for alternate functional hardware that is enduring and functional when installed into a fiberglass hull. He, like so many other fabricators, continues to strive to propel a great concept to the next dimension.  

Premium storage

Every vessel, no matter how large or small, needs optimized storage space, which is always tight onboard. Crew and owners need most items to be securely stowed away, yet they want easy access to everything from hardware to comfortable quilts.

Clever storage was recently created in the armrests of a custom-built sofa by Canvas Designers Inc., Riveria Beach, Fla. In fact, this upholstery project was awarded an Award of Distinction in the MFA 2016 Fabrication Excellence Awards. This custom sofa was for a 72-foot Merritt Sport Fish.

The two sofa arms of this handsome U-shaped sofa provide spacious custom storage via a hinge access feature. [Terri, this project was included in the March/April 2106 issue of MF (MFA Fabicator Awards). It stated “The entire seat and back are on hydraulic hinges, which lift up for storage space.” I think I should add this.]

Pat Erickson, at Canvas Designers, says the company slogan is, “If you can dream it, we can make it.”

The sofa is all leather with the back sections custom built with 2.25-inch horizontal channel pockets. The foam pockets were individually fabricated with a Stamoid back base for stability. The back has zipper access for stuffing the foam into the individual pockets. The size was specified by the client to match the leather boat blinds. This custom feature on the sofa back was exactly what the customer envisioned.

Just last week I received a customer request to include armrest storage in new custom sofa on a family vessel that is in a full refit stage. The customer saw this feature on the Internet and at a boat show. This opportunity illustrates how important it is to keep up with design trends for seating and cushions through Marine Fabricator magazine, seminars and conventions.

Climate controlled seating

Bill Marriott from Extreme Upholstery Designs, Charleston, S.C., is a talented fabricator who recently exceeded a customer’s expectations by creating climate-controlled mezzanine seating. He described the request as a “brain teaser, to say the least.” He puzzled through every step before preparing a prototype. Many times this type of process can take a fabricator days or weeks. I like to call it “chewing over a project.”

Bill’s client flew him to the boat site, so he could pattern the seat area on a new custom-made 62-foot Scarborough in North Carolina. The resulting seats are climate controlled with heat and air conditioning, so the owner can have a cool ride after a long hot fishing trip. Sunbrella® fabric was used. The one requirement the client had was, when standing on the dock or the back of the boat, he did not want to see into the open holes where the heat and air comes through the seat. Bill designed the seat so that only the fabric was visible when looking at the openings.

This was no easy task for a three-dimensional seat, which required access to insert the foam on form fitting cushions. Talent, ingenuity and years of design skills were incorporated into this amazing creation   .

Here are preparation tips that can guide you in creating a challenging project.

  • Do a conceptual “walk through” for each stage of a unique project to ensure that your time and talent are adequately compensated.
  • Confirm materials and hardware.
  • Prepare a maquette, sample or pattern.
  • Consider contours and alignment of all areas.
  • Determine time factors for each stage.
  • Determine what employee training may be required for the project.
  • Determine installation logistics and storage-related issues.

Don’t be shy about calling on fellow fabricators for advice when you hit a roadblock. You will be surprised at how willingly they share resources related to suppliers, techniques and professional contacts. I recall reading about scrim foam in the Marine Fabricator magazine several years back, I did not know what this foam was or how it would be utilized, so I contacted the author. She was more than willing to explain the various types and usages and provide a list of vendors. Through reaching out to others, I am fortunate to have many friends in this unique industry.

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Fresh updates for older vessels

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Terri Madden’s January/February 2017 article for Marine Fabricator Magazine.

Most interior fabrication projects occur on fixer-uppers. The vessel might be vintage or it might be less than ten years old. While I always welcome the challenge of doing a better design than the original, there is a fine line between aesthetics and practicality. After all, the boat needs to be both comfortable and secure while cruising on the water.

Your personal and professional marine expertise is what draws in a client, but your finished project is what leaves a lasting impression with everyone who steps on board. Do your best early in your client discussions to understand the scope of the job, budget and deadline. Be creative in offering phases for a project if a customer request surpasses the budget. Be inspired by the vast selection available for indoor and outdoor textiles and the marine hardware and components that offer performance whether attached by tracks, snaps, magnets or one of the numerous Velcro® systems.

Help your clients understand that a lot goes into any marine fabrication project. Your customers will appreciate your guidance and knowledge on how to choose textiles that “look good and stay in place.” And do research on emerging trends on fabrics and components so your next project reflects a fresh design while representing tried-and-true fabrication techniques.

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Photos 2-5. Fresh colors and patterns to consider in interior design updates include aqua, black and white, citron, neutrals and mauves and neutrals and yellows.

Fabric trends

Observe your client’s sense of style and how he or she likes to dress. Does he or she favor a tailored look or a more casual shabby chic style? He or she may request boat decor in a similar style. Fabrics set the tone on any interior and are available in every option from basic nautical stripes and patterns, starting at around $18 per yard, to impressive designer jacquards, costing more than $150 per yard.

Do your research to understand the trends for the particular model and year of the vessel, keeping in mind that your upgrades will add value to the boat. My first client wanted his Bertram 50 foot to look exactly like the boat’s catalog, so that was exactly what we provided. Years later his grown son purchased a 1996 Bertram 50 foot which we restored in a manner reminiscent of the family’s original boat.

Be knowledgeable on other trends related to boat interiors. For example, classic interiors that include wall panels and headboards are currently incorporating extra padding and height, and tufted buttons are being utilized on headboards and sofas. Textile patterns are being juxtaposed to provide drama and flair.

Acrylic yarns have been incorporated into every imaginable color palette with textures and designs that reflect current trends. Marine designs with patterns, colors and textures are a bit more challenging than a residential or commercial project, because most cabin areas are visible on vessels up to 50 feet. It is a good idea to keep in mind the boat exterior colors. The waterline and hull colors are no longer a traditional white, so this is a good lead to follow in knowing a customer’s color preference.

Interior harmony is essential, especially after being outdoors at sea all day. Navy, yellow, orange or gray are common colors to choose. For larger vessels, it is a fabricator’s dream to utilize various palettes in individual cabins.

Most marine vendors launch their indoor and outdoor fabrics in the fall for the following year. You can get great ideas by contacting IFAI vendors now for 2017 color cards and fabric books. Observe trends in design magazines and visit local boat shows (see dates and listing on page 12) and the Marine Fabricators Convention from January 19–21 in Jacksonville, Fla., for more ideas. If you’ve never visited the IFAI Expo put it on your calendar now for September 26–29 in New Orleans. If it’s been awhile, attend this year to learn more about systems you will find useful on your future projects.

Fabric performance factors

It is important to be knowledgeable about manufacturers’ data or warranty information that is listed on their material specification sheets. Explain the important performance specifications to your customers. They will appreciate your expert advice on abrasion resistance, UV resistance, flammability, care and cleaning.

Durability. I first heard about the Wyzenbeek Test when I was obtaining a degree in textile design. This test should be kept in mind for making the best fabric selections for a project. The Wyzenbeek Test is regarded as the standard of measuring abrasion resistance or strength for fabrics in North America. Double rubs (each back-and-forth motion is one double rub) are a measurement of a fabric’s abrasion resistance. The double rubs you should look for in a fabric depend on your intended application.

In general, around 15,000 or more double rubs is considered heavy-duty for residential applications. We actually have commercial designers and customers who request 35,000 to 85,000 double rubs for their fabrics. Such fabrics are recommended for constant use, as in hospital waiting areas, airport terminals, restaurants, theaters and commercial vessels. There are vinyls that exceed 200,000 double rubs.

UV resistance. I am sure every fabricator has received at least one request to replace a cracked or brittle seat due to sun damage. Most suppliers of marine textiles include specifications with their product samples, so customers know how well the fabric will stand up to ultraviolet rays. Generally, fabric is rated for how well it will hold up under sun exposure ranging from 650 to 2,200 hours. The AATCC TM186-2015 Weather Resistance test measures a textile’s capacity to withstand UV light and moisture exposure.

Flammability. Flammability is the capacity of a substance to burn or ignite, causing fire or combustion. The flammability information generally listed on the supplier data sheets is the CAL 117E Test, but other tests may be included. The “passes” rating covers upholstery fabrics and filling materials and tests the interaction of the materials used in a piece of upholstered furniture. It is an important rating to be aware of.

Care and cleaning. We’ve all been asked to replace soiled cushions and other items that are more or less ruined. Often these items were provided by another shop. This begs the question, how many of us follow up with customers to see how well our projects are holding up? Providing follow-up after a year or so shows your genuine concern about quality and can often lead to more work.

Many fabricators are affiliated with a cleaning service that they recommend to customers. After a boat spends a year in the tropics without cleaning and maintenance, it is not easy to remove soil and stains from exterior applications. Yet some exterior fabrics now boast a five-year warranty with proper maintenance. I recently removed stubborn stains on a fabric that noted bleach could be used. To my surprise, Clorox Gel removed these deep stains. Be sure to test an area before proceeding with any strong stain remover. Again, most textile manufacturers include care and cleaning guidelines on their specification cards.

Hardware

Snaps, zippers and Velcro are traditional means of securing cushions in place, and several varieties of each exist. A Snad® is a plastic adhesive snap component that is available from YKK. It is available in various configurations for domed configurations or areas where a flexible base is required. It allows a snap to be adhered to a base where drilling a hole is not an option.

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AquaGuard®/Vislon® and Proseal zippers are great options to integrate into your new fabrications.

Zippers. Have you seen the glow-in-the-dark and reflective coil zippers? How about the AquaGuard®/Vislon® zippers from YKK? These can be incorporated into exterior pillows and gear. The Gooper Hermetic magnetic zipper by Paskal works well on outdoor applications. The Gooper technology integrates rare-earth magnets with a flexible thermoplastic polyurethane (TPU) strip to provide a waterproof, dust-proof hermetic seal. I am currently using the Gooper on an exterior cover on a stainless Jacuzzi® where snaps are not an option for securing the cover. It works well because the magnets will hold the sides in place.

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The Gooper Hermetic magnetic zipper provides a waterproof seal.

Velcro. Industrial-strength Velcro Extreme fasteners feature an all-weather, UV-resistant adhesive for all surfaces. This is a handy option for indoor and outdoor applications without using drills, nails, screws or epoxy. It is a durable alternative for attaching seating, and it is frequently used for ceiling and wall panels and headboards on every size of boat.

 

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Snad® adhesive snap components are available in various configurations and require no drilling.

What projects do you have coming up this year that push traditional boundaries for solutions? I would enjoy receiving any questions and feedback on how you have incorporated my recommendations and techniques into your projects. You can contact me through my website at http://www.sandseaair.com. I wish all my readers a blessed, healthy and prosperous 2017!


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Restyled sleeping cabins

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Terri Madden’s May/June 2016 article for Marine Fabricator Magazine.

Interior sleeping cabins on a vessel have always been my favorite projects. I enjoy researching options and ultimately providing customers with tidy solutions that offer easy accessibility.

Cabin spaces and mattresses come in all shapes and sizes. One of my clients claims to sleep 14 people on his 54-foot Bertram with only three interior cabins, but that’s a story for another time. On my first sleeping cabin project, the vessel had no foam or mattresses, and the sloping hull areas required patterning that I could barely fit into. A recent project on a Ferretti master cabin had a walk-around queen bed and headboard with massive oval windows at sea level.

Plan the job

  • Determine the time needed to do the job. This is essential in putting together your quote to know what your profit on the project will be.
  • Determine qualified personnel to pattern, assemble and remove items from the vessel.
  • Identify adequate machinery and equipment to complete the project.
  • Purchase the materials, keeping in mind availability and delivery issues.
  • Determine what fabrication skills are required to do the work. Decide what work can be done in-house and what duties will be outsourced. For example, who will do quilting?
  • Determine the process and dates for re-installation of items removed from the vessel.
  • Under promise, over deliver.

Start with good communication

When meeting a potential customer, good communication sets the stage for a successful project. Keep in mind that your customer may be unsure of your skills and how the design process works.

Develop your plan based on the facts you received over the phone or in person. Do as much discovery ahead of time and prepare a list of the key points that you and the customer must address in your first meeting. Research the vessel: know the model, year and size. Find out the customer’s primary goals, time frame and budget.

Listen to what your customer is asking for, confirm and recap the key items that were mentioned and requested during your meeting. Be honest if this is work you can provide. Then let your customer know when you will get back to him or her to offer your best recommendations.

For new cabin interiors, having a second meeting is generally necessary. You will want to discuss material selection and confirm layouts, styles and measurements, especially if design changes are being made rather than duplicating existing covers and window treatments. Take plenty of photos of all cabin areas; these will be invaluable references during your project.

Many materials are suitable for interior marine applications. I recommend offering your customer two groupings that will accommodate the agreed-upon budget and time frame of the project.

Once an agreement is reached, it is time to get started. For a recent master cabin project, the decision maker lived “off island.” She requested new textiles for the master cabin of a 60-foot 2003 Viking. The four coordinating textile patterns were selected online during a phone conference for the following:

  • A three-part headboard
  • A queen-size bed frame in one large section and two smaller sections
  • A fitted quilted bedspread for the existing mattress that sits within the bed frame
  • Two pillow shams with accent trim
  • An oversized neck roll pillow
  • Navy-colored fitted sheets in 100 percent cotton and 600 thread count.

Selection of materials

Fabric selection can be a daunting process unless your customer knows what he or she is looking for. Some customers know what design theme and colors they prefer, such as casual nautical styling or more sophisticated residential bedding. Because fabrics vary widely in cost, it is important that you and the customer agree on the budget, particularly because bedspread quilting and specialty fabrication quickly add to the budget.

Our showroom offers a large selection of indoor-outdoor fabrics from which our customers can choose. However, sometimes customers select online fabrics, as did our customer. Because she
selected four online fabrics, this required extra time. Her choices appeared to be a good match on the computer monitor, but they were very different “in hand.” Be certain to give yourself sufficient time to request and receive samples before purchasing.

What appeared to be plenty of time turned into a final rush to meet our deadline due to unforeseen decisions and delays. The delays occurred for reasons outside our control, including:

  • An additional two to three weeks was needed, as we waited for the requested samples of the original four fabrics. Two fabrics were woven patterns that were fine, yet the main fabric for the bedspread was a bright print that did not match the other materials. Time slipped by as we sourced the best replacement fabrics and waited for new memo samples.
  • A matching solid blue fabric was needed for the bed frame, because the original choice was back ordered past our delivery date.
  • Extra time was needed to verify that all fabrics were in stock and ready to ship.
  • Photos of replacement fabrics were sent to the customer, then we waited for her final approval.

Even though a local company had agreed to do the quilting, the wait time was more than a month after it received the fabric.

We needed additional time for the in-house quilting and procuring a large matching flat sheet for the lining and the Dacron® fill.

Some of you specialize in interiors and provide fitted quilted bedspreads. However, if you want to begin offering this item, be aware that a standard 54-inch fabric has to be pieced evenly on each side of the center of the 54-inch fabric to look and fit correctly on a master stateroom mattress.

This type of mattress can measure more than 65-inches wide.

Once you have an extra large size for the length and width, plan the quilt design that can be anything from an outline pattern to an hourglass pattern. For our project we decided on a diamond motif.

Over the past few years, several of our clients have purchased flat quilted bedding from online sources like Pottery Barn. We then adapt the quilt to the mattress shape. This is an affordable option you may like to recommend, especially for bunk beds.

For those who would like to offer quilted bedspreads, Tabors of San Angelo Inc. is a custom workroom in San Angelo, Texas, that provides high quality quilting for bedspreads, pillow shams and pillows. We have used this company in the past. You can send them a pattern with specifications, request a catalog or contact them at http://www.taborsofsanangelo.com.

Fitted sheets

The original mattress shape was designed to permit movement around it on three sides. The headboard was angled, and the rest of the mattress was one long curve. Including fitted sheets with an order is a nice addition for an irregular mattress. I always recommend starting with a king-size sheet set, which may seem large, yet it allows for adequate yardage for the fitting cuts, darts and a new elastic casing under the mattress.

Follow these steps to make a fitted bottom sheet:

  • Cut off the elastic band close to the edge of the sheet.
  • Place the sheet over the mattress so that it hangs down evenly at the sides from the top.
  • Use any of the original darts at the corners that may work.
  • Continue to dart the corners and transitions around the mattress as needed, usually four to six darts.
  • Mark the sheet at 17-inches down from the top edge; this will be your cut line and edge to turn, fold under and stitch closed with a half-inch elastic within the new casing band.
  • Stitch in the original care label at the head of the sheet for customer identification when making the bed.

Our order for the king fitted sheet set was placed online at Bed Bath & Beyond, because it was one of the only sources that had navy 100 percent cotton sheets in 600 thread count.

After two weeks and no delivery date or tracking info, I placed a replacement order. Unfortunately, there were no sheets in this style and color available. A nearby Macy’s had navy sheets but they were in a 500 thread count. Once again, more time was needed to contact the customer, get her approval, then order the sheets. Almost three weeks later the sheets had not arrived. Tick Tock. The original lengthy deadline was closing in.

Delivery time

The delivery date was less than one week away when everything finally came together. The anxious customer was thrilled to receive photos of the completed project. From there, the mattress and bed frame were installed on time. The customer loved the fitted sheets and coordinated look that fit together like a jig-saw puzzle.

Even with vision and careful planning on a project, sometimes we have to step back, evaluate and add more time to our estimates. Obstacles can cause delays and stress. That stress can eclipse a team’s feeling of pride over a successful project. At the end of projects, take time to think about what you’ve learned. Try to recognize early red flags that you perhaps overlooked. Finally, acknowledge all the things you did right to deliver a quality project.


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Meticulous prototyping leads to attractive cylinder cushions

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Terri Madden’s September/October 2016 article for Marine Fabricator Magazine.

You can browse the PDF, or read the text version below.

Approaching a project with cylinder cushions is kind of like trying to put a square peg into a round hole, you have to approach the solution by thinking “outside of the box”. The box being what we are familiar with when constructing cushions – foam in rectangular shapes, cushion covers with standard size side bands and upper and lower faces of equal dimensions. Ok, so you’re starting to get the picture, or you’ve visited a job site and been requested to fabricate cylinder cushions; all of the sudden you’re walking on uncharted territory. You can approach the challenge by welcoming it as a learning opportunity and break down the stages into manageable sections. If there are multiple pieces, you’re already a step ahead as fabricating more than one piece will add to your profit ratio.

Over the years we’ve been asked to fabricate several unusual items that may or may not be a product that we have no way of knowing if it will be a “one hit wonder” or an item that will “take the market by storm”. A while back we started charging a prototype fee, a few hundred dollars to develop and fabricate a concept for a customer, a prototype then goes to a set price based on the final quantity. We consider the customer and this price sheet found on the Internet:

Price List

I design everything – $100

I design – You watch – $200

I design – You advise – $300

I design – You help – $500

You design – I help – $800

You design – I advise – $1300

You design – I watch – $2100

You design everything – $3,400

This pricing may or may not apply to your project, yet do consider the learning curve if you’ve never fabricated a cylinder that will attach to tubing. I recommend setting aside several hours of uninterrupted time to develop the concept and fabricate prototypes in order to evolve the best solution when you do not have a pattern or a good existing cover that you can take apart for your project. When you build this factor into your project, the understanding that you are being compensated for your talent, will inspire your solutions and result in an award worthy project.

If the customer wants to use existing cylinder foam, evaluate how the foam shape has conformed to the original covers and if at all possible, move forward with new foam. This is very important as the old foam may need a topper in order to properly “fill out” a new cover! You can order dry-fast foam cylinders, cut to size, available in three densities of firmness, including the cut-out for the tube in the cylinder center. On the illustrated sketch you can see the diagram we submitted when we ordered new foam from Reliatex Inc. They have facilities in Jacksonville, Tampa and Miami, Florida. Be sure to allow sufficient lead-time for any supplier to cut and ship your product.

Getting Ready to go for the Gold

Ok, so now you’ve analyzed the task, the quantity and style of cylinder cushions, and determined a price that you and your customer find agreeable.

When we measured the original cylinders we realized that they were all slightly different lengths and that one standard size would work well within the tubing frame spaces. Additionally, a standard size would be less production time vs. custom sizes and the overall project would be more visually appealing. We include an extra 1/2″ more or less for our finished foam size (based on the foam density) when ordering new foam, so that the foam “fills out” the cushion cover.

As the actual time for fabrication approaches, having the foam cylinders on-hand is essential for proper pattern placement and achieving the best final fit.

For this project we approached the cylinder design and prototypes without an original pattern, since the original covers were not the quality that we would replicate. Now our basic guidelines were our roadmap to reach our goal to design and fabricate tasty cylinder covers to fit over the stainless tubing; cylinders with an 8” diameter and a length of 27”. It was now in our hands to make removable covers for 4 cylinders with inserts in medium density foam, which would provide sufficient for firmness for seat backs so guests could enjoy relaxing moments while at sea.

In the past we fabricated jacuzzi pool cushions on tubing that helped us in our approach for this project. The jacuzzi cushions were designed for a more permanent location, whereas the cylinders for this project needed to be removable by the crew on a 42’ catamaran.

Our Solutions

  • We started with the round ends first. The circles were cut to include a 1/2″ seam. We cut two – 8” circles of vinyl for each side. We generally cut our foam and material the same size in order for the foam to “fill-out” the cushion cover after the seam allowance reduces the cushion size.
  • We placed the vinyl circles face to face.
  • On the inside of the vinyl we marked the center hole for the tubing cut-out and a line for an opening along 1/2 of the diameter for an access opening, when the finished cylinder would need to be placed over the tube.
  • We stitched along outside of indicator line for the opening slit, around the circle for the tubing and down the other outside line for the opening slit.
  • We cut next to the stitching between the lines for the access opening and around the center hole – removing the excess at the center hole.
  • We turned the layers to the right side and top stitched the layer opening “in place”. Then we trimmed the inner facing layer as seen in the photos.
  • The cylinder ends would secure closed with a Velcro flap whereas the center of the cylinder would incorporate a #5 jacket zipper. The tails of the jacket zipper would hide inside of the sides of the cylinder and be accessed via the Velcro opening and closing next to the tubing.
  • A piece of 2” Male Velcro formed the flap as one edge of the Velcro was sewn to one side of the opening under the tube hole and a piece of 1” Female Marine Velcro was sewn to the other side of the 4″ opening. This insured that the area would hold tight in a closed position when the cylinder was placed on the tube. See photo.

I’ve included a few photos of the Jacuzzi cushion that was made with the zippers extending into the side ends showing the stitching sequence & pole placement cut-outs, which were underneath of cushion zipper.

  • The cylinder center was measured and cut with seam allowances included for the zipper.
  • The two ends of the cylinder were sewn to the center panel
  • The jacket zipper was sewn to a turned edge of the center panel, leaving a 3″ tail at each end, where the cylinder side ends met the center panel.
  • The foam was inserted into the cover (we spray a dry silicone when inserting foam into covers, as it reduces the resistance of the foam and material).

I included photos of a unique striped canvas cylinder project that we observed on a vessel, cushion covers definitely in need of replacement, yet the vessel was not in San Juan for the project to be realized.

The finished cylinder could be easily placed on the tubing, inserting the foam over the tubing, closing the zipper (tucking the zipper ends into the foam and securing the end circles via the Velcro. By carefully maneuvering the foam at the cylinder ends the male and female Velcro would secure/close the space below the tubing to where the zipper connected. The end result was sleek cylinders with hidden access areas for easy removal and installation. Additionally, at the time of installation we wrapped the tubing with nonskid to hold the cylinders “in-place”, as the original cylinders had unsightly zippers, which displaced to various locations on the tubing.

Not only were we proud to deliver a handsome project, the captain and owner were equally pleased. The design and fabrication process is in our library of cushion styles and will certainly be a valuable example when the time comes to reproduce cylinders that fit into and on special spaces that require Stylized Solutions!


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Elegant performance in stripes

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Terri Madden’s March/April 2016 article for Marine Fabricator Magazine.

You can browse the PDF, or read the text version below.

Stripes come in every color, shape and size…a two-color stripe can even be juxtaposed to form an eye-catching pattern. Striking stripe patterns can be matched or combined with solid colors to provide dramatic effects for your next project. Stripes are more popular than ever and Sunbrella likes them so much that they featured subtle as well as dramatic stripes on their 2016-2017 Upholstery Fabric Brochure. Stripes can be placed horizontally or vertically to give a low and wide effect versus a high or tall dimension to a space. As Marine Fabricators, we even get to play with stripes around curved edges and contour corners. The sky is the limit, yet we need to apply some earthly planning to ensure that incorporating stripes into a project is a winning solution.

Every year new patterns and colors are developed that invite fabricators to create different looks on board a yacht; classic, modern, chic or sophisticated. A sailor stripe sets off an eye-catching look, especially when combined alongside various shades of brilliant oranges or you can offer a subtle pallet of clay and charcoal that is a modern interpretation of European inspired designs with architectural precision.

If you’re not familiar with fabricating with stripes it can be a bit of a challenge, yet you can welcome the opportunity, as stripes are synonymous with boat décor and make a dramatic nautical impact on any yacht and your choices of colors and sizes are endless.  I was a bit daunted as to how to proceed for a few of the projects and spaces that will be explained and illustrated in this article. I want to give you that ‘step-ahead’ when your next customer inquires and selects a striped marine textile for their boat. Some essential design elements for you to consider are the following:

The Repeat of a Fabric

The repeat of a fabric refers to the number of inches it takes before the pattern starts all over again. It is the distance between the starting point of the pattern to the point where that pattern starts over again. This is referred to as “one repeat.”

Screen Shot 2016-06-29 at 2.49.09 PMWhen choosing a fabric for a project, it is important to know the repeat of the pattern you are considering.  The repeat can have a big impact on how much fabric you need, and what that product looks like on a sectional seating with multiple cushions compared to a single cushion.

Any type of patterned fabric will always have a repeat, and the supplier generally provides this information.

The average repeats size of a stripe is between 8” and 9″. A cushion layout needs to be planned ahead of time, for ordering the correct quantity of fabric as well as the best use of the material.

Recently we provided a few color ways to a customer in a handsome nautical stripe. We received two swatches from a supplier of the nautical pattern below; one was a navy/white/tan color way and the other was a teal/white/navy color way. The customer selected the navy/white/tan color way and when we went to order the material we were told that the pattern repeat was 16″. Ironically the teal/white/navy color way was a continuation of the navy/white/tan color way, yet with several more white stripes, which our customer did not want. Additionally, the 16″ repeat would have been extremely difficult to pattern as well as a significant amount of fabric waste for matching cushions that would sit “side by side.”  Below are two swatches sewn together to show the full repeat!

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16″ Fabric Repeat

Also, it is always wise to have your customer select not only their first choice of material for a project, but also a second choice as time between fabric selection, confirmation and you ordering materials may result in your customers #1 choice not being readily available.

Location

Determine the cushion(s) placement, will it be side-by-side, will there be a corner cushion that joins next to other cushions to form an L-Seating area?

Design of the Cushions

What will be the cushion style? Common types are: rollover designs with side bands, rollover designs with corner seams, rollover designs with baseball corners, Side bands in a contrasting stripe placement, Side bands in a solid matching fabric.

If the cushion is a banded cushion, you have three options:

Vertical Stripes

The contrast of a horizontal band to a vertical stripe on the band of the cushion actually can work nicely depending on the stripe.

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Vertical vs. Horizontal Bands

When the face of the back cushion runs vertically, your seat cushion stripes must be patterned so that the stripes match perfectly. A piping accent may be used to enhance the construction transition to a side band in the horizontal or Vertical direction and consistency should be your guide for all cushions.

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Solid Color Band

This can be your best option whether you are just getting started working with stripes, or an experienced fabricator. A solid border and band work nicely when you have a contour corner area to fabricate.

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Above is a combination of a stripe fabric insert with a solid border in a marine vinyl.

It is wise to photograph the area and then sketch or draft examples over the area for consideration to determine the best option for your material direction, project space and a budget when you are estimating time and cost; as project planning, layout and construction time can easily add up when multiple pieces are part of a large layout, as seen below.

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One of my all-time favorites is this Ralph Lauren stripe, juxtaposed for a classic and dramatic impact! Note the stripe placement on the top bands of the corner cushions.

I’m including a few photos of our projects as well as some interesting others that illustrate the variations I’ve explained above. Look around and notice the placement of stripes on cushions and pillows whenever you see them in a residential, commercial or marine project. Trust your instinct, as to what works best or do a mock-up to guarantee a winning combination.Screen Shot 2016-06-29 at 2.50.53 PMThis master cabin bedcover works well with the horizontal stripe on the side banding. The border stripe on the accent pillows unites the patterns for a cohesive look.Screen Shot 2016-06-29 at 2.51.03 PMThese contour cushions are sewn with the stripe as an insert and solid banding and edging on the seat cushions – found on the web – however, notice that the top left back cushion stripes do not match the seat stripe!

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An inviting aft cushion seat, seen at a recent boat show.

In the seating images below I am certain that someone spent a significant amount of time planning and fabricating these striped seat cushions. The side band makes a nice transition on the double seat with a baseball corner. The solid piping provides a clean transition to the stripe in the horizontal direction on the double seat.

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Double Seat – Horizontal Side Band, Baseball Corner, Solid Piping and Rollover Face

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However, I imagine we could all enjoy contemplating the various solutions as to our “best shot” for the corner cushion when a rollover design with this stripe was planned for the multiple seating on this yacht. Send along your thoughts, ideas and any photos you have for a similar project that you may have encountered, I’m interested and welcome your input!

May you enjoy ‘Smooth Sailing’ into Spring!