Sew a Bench Cushion Cover with Zipper: Learn it in Minutes

Are you tired of your bench cushion cover looking dull and worn-out? 
Why not try making your own?! 
As someone who loves to sew, I can assure you that sewing your own cushion cover and making an entire cushion with a zipper is easier than you may think. 
Plus, you’ll not only save money, but you’ll also have a customized, unique piece to show off to your friends and family.

Gathering the Materials

 Sewing a bench cushion cover with a zipper is a great way to add a personal touch to your home. The first step in creating a beautiful bench cushion cover is gathering all the materials you’ll need. Don’t worry, I’ll guide you through everything you’ll need!

  1. Fabric: Choose a decorative fabric that is durable and easy to clean. Upholstery weight fabric works best. You’ll need enough fabric to cover the bench cushion, plus extra for the sides and the zipper.
  2. Zipper: Choose a zipper that is the same length as the cushion. A #5 or #7 gauge zipper is a good choice for a cushion cover.
  3. Thread: Use a high-quality thread that matches the color of your fabric.
  4. Sewing machine: A standard sewing machine with a zipper foot and straight stitch is all you’ll need for this project.
  5. Pins: You’ll need pins to hold the fabric in place while you sew.
  6. Scissors: A good pair of scissors will make cutting a solid fabric much easier.
  7. Measuring tape: Measure your bench cushion to ensure you purchase the right amount of fabric.
  8. Iron: You’ll need an iron to press the fabric and seams as you work.
  9. Straight edge to mark the cut line

Now that you have gathered all the materials needed to start the project, you’re one step closer to creating a beautiful bench cushion cover. In the next section, we’ll discuss the steps needed to prepare and cut the fabric. 

Taking Measurements: The Starting Point of Every Successful Project

Once you have everything, measure the entire length of the cushion, width, and height. You’ll want to add 1 inch to the length and width for seam allowance, and an additional inch to the length for the zipper.

Having spare meat on the sides of the fabric is always going to help you.

Some tutorials call for you to create a bottom panel first but we will do it differently.

If you have raw edges you can sew a long strip onto it to protect it. 

This can be fixed with spray adhesive prior to sewing. (My little trick) 

Secondly, you will need to take accurate measurements. One of the things I can occasionally get wrong. Opps!

In this case, we need to measure the bench to determine the fabric dimensions and how much material we’ll need. It’s important to take your time with this step and make sure your measurements are as precise as possible. Here are some tips for taking accurate measurements:

  • Use a measuring tape: A measuring tape is the best tool for measuring because it’s flexible and easy to wrap around curved surfaces, like bench cushions. You can find them at any craft or hardware store.
  • Measure twice: It’s always a good idea to measure the area twice to ensure the dimensions are correct. If you get two different measurements, measure a third time to confirm the correct one.
  • Account for the cushion thickness: Don’t forget to factor in the cushion thickness when measuring. Measure the cushion at its thickest point to ensure your cover will fit snugly.
  • Record your measurements: Write down your measurements as you go to avoid confusion or forgetfulness. It’s especially important to label which measurement corresponds to which part of the cushion.

Once you have your measurements, you’re ready to determine how much fabric you’ll need. To do this, you’ll need to calculate the total surface area of the foam cushion by adding the length and width measurements and multiplying by two. Don’t forget to add a few extra inches to the length and width to accommodate the seam allowance and the zipper. Do you need side pieces? How tall is 
Taking accurate measurements is crucial to the success of your sewing project. By using a measuring tape, measuring twice, accounting for cushion thickness or upholstery foam, and recording your measurements, you’ll be well on your way to creating a beautiful and functional bench seat cushion cover. Always make sure you have some extra fabric. 

It’s not every day you make replacement covers.

The end result is to have full-looking cushions 

Cutting the Fabrics

Alright, let’s dive into the cutting process! Before we begin, make sure you have all the materials, including the fabric bottom pieces, a rotary cutter, cutting mat, ruler, and fabric scissors. And don’t forget to measure twice and cut once!

First, we need to determine the dimensions of our fabric pieces. Measure your bench cushion and add 1 inch to both the length and width for seam allowance. 

For example, if your cushion measures 48″x16″, you’ll need to cut two pieces of fabric that are 49″x17″.

Next, place your fabric on the cutting mat, making sure it’s smooth and flat. If your fabric has a pattern, make sure it’s facing up. Use a rotary cutter and ruler to cut straight lines along the edges of your fabric, according to your measurements.

Repeat the process for the second piece of fabric, making sure that it’s cut to the same dimensions as the first.

Now, we need to cut the zipper panels for the back. Measure the length of your cushion and add 1 inch for seam allowance. Then, divide that number by two. This is the measurement for each zipper panel. For example, if your cushion is 48 inches long, each zipper panel should be 25 inches long.

Cut two pieces of fabric to the desired length and 4 inches wide. These will be your zipper panels.

Lastly, cut the remaining fabric into two identical rectangular pieces that will serve as the sides of your cushion cover. To determine the width of these pieces, measure the height of your cushion and add 1 inch for seam allowance. To determine the length, add 1 inch to the length of your cushion and multiply that number by 2. This will give you enough fabric to cover both sides of your cushion.

That’s it for cutting! In the next section, where we’ll begin sewing our cushion covers together.

Sewing the Cushion Cover

Now, we’ll put everything we’ve learned together and start sewing the cushion cover!

  1. First, lay out your fabric with the right side facing down. Place your cushion on top and cut the fabric to size, leaving an extra inch or two on each side to account for seams.
  2. Sew the zipper onto one of the short edges of the fabric. Pin the zipper in place and sew along both sides, making sure to backstitch at the beginning and end to prevent unravelling.
  3. Fold the fabric in half, right sides facing each other, so that the zipper is in the middle. Pin the two remaining sides together and sew, again backstitching at the beginning and end.
  4. Finally, turn the cover right side out and insert your cushion.

Remember, if you want a removable and washable cushion cover, be sure to use a zipper!

Don’t worry if this is your first time sewing – practice makes perfect. Take your time and double-check your measurements and sewing lines to ensure a perfectly fitted and professional-looking cushion cover.

Sewing your own cushion cover has never been easier! With a few basic sewing skills and the right materials, you can create a custom cushion cover that perfectly matches your style and decor. So go ahead and give it a try – you might be surprised at how satisfying and rewarding it can be to create something with your own two hands.

Adding the Zipper and Finishing Touches

Now that we have finished sewing the cover, it’s time to add the zipper and finishing touches to complete the look. Here are the steps to follow:

  1. Measure the length of the zipper and mark the center of the back panel where the zipper will be added.
  2. Pin the zipper onto the center mark, making sure the teeth of the zipper face down towards the fabric.
  3. Using a zipper foot, sew the zipper onto the fabric, starting from the top and going all the way down. Make sure to backstitch at the beginning and end to secure the zipper in place.
  4. Once the zipper is sewn in place, it’s time to finish the edges. Trim any excess fabric to create a neat, professional finish.
  5. Fold the fabric over the zipper and pin it in place. Sew along the edge to secure the fabric in place.
  6. Lastly, turn the cushion cover right side out and admire your work. You have created a beautiful cushion cover that is both stylish and functional.

Remember, these steps are just a guideline and you can adjust as necessary based on your skill level and preference. Don’t be afraid to get creative and add your personal touch to the cushion cover.

So there you have it, adding a zipper and finishing touches to a bench cushion cover is simple and easy. Now you can enjoy your new cushion cover and show it off to your friends and family. Happy sewing!


That’s it! I’ve walked you through the process of creating a beautiful and functional bench cushion cover that will elevate your home decor to the next level. Crafting something from scratch and seeing the end result is so rewarding, and it’s especially satisfying when you get to enjoy it every day.

It’s clear that a little bit of effort and a few hours of your time can pay off tremendously in the long run. You’ll save money by creating your own cushion rather than buying one, and you’ll have something that perfectly matches your style and space.

Remember, it’s important to measure accurately and take your time while sewing to ensure that the finished product looks professional and polished. Don’t be afraid to experiment with different fabric types, colors, and patterns to create a custom look that’s uniquely you.

Overall, I hope you found this tutorial helpful and enjoyed learning how to sew a bench cushion cover with a zipper. Feel free to share your creations with me, I’d love to see them!

Follow Us

Recent Posts

The Best Cordless Iron for Quilting: My Top Picks and Reviews

The Best Cordless Iron for Quilting: My Top Picks and Reviews

Ironing clothes and fabrics is a necessary but often tedious task. Every quilter knows the importance of having a good iron for their quilting projects. Finding the best option of iron is crucial in order to ensure that quilt blocks are perfectly pressed and stubborn...

Handheld Sewing Machine Reviews: My Top Picks for You

Handheld Sewing Machine Reviews: My Top Picks for You

I've always been a fan of handheld sewing machines. They're just so convenient, easy to use, and perfect for those quick fixes or small sewing projects. Now, I know there are countless options out there, and it can be overwhelming to choose the right one. That's why...

How Do You Calculate Binding for a Quilt: A Guide

How Do You Calculate Binding for a Quilt: A Guide

Calculating binding for a quilt is an important and necessary step in the quilt-making process. Binding refers to the fabric that is sewn around the edges of a quilt to finish it and give it a polished look. It's important to properly calculate the binding needed for...

How to Make a Bargello Quilt: My Quick & Easy Guide

How to Make a Bargello Quilt: My Quick & Easy Guide

You know, making a Bargello quilt can be a surprisingly simple and satisfying project for both newcomers and experienced quilters. Contrary to what you might assume, no, you don't have to be an expert in the art of quilting in order to create a beautiful...