Project: How to Sew Boler Trailer Cushion Covers

How to sew Boler trailer cushion covers – it’s easy! It just takes a lot of planning, patience and precision (well, sort of). First, head to your local fabric store and buy enough fabric for however many cushions you need to cover. I usually buy about 9 metres of fabric for all 9 cushions, if it’s 60+ wide. This sometimes leaves me tight margins, yet as a back-up, you can use a complimentary fabric for underneath the bunk, the banana cushion, or the two small dinette cushions. Okay – let’s get sewing!

What You Need:

• Boler cushions that are pre-cut
• Fabric – at least 9 metres of 60+ width
• Quilting measuring tape
• Fabric pen/chalk
• Scissor
• Pins (a lot – at least 50)
• Zippers (use duvet zippers for the large cushions)
• Thread
• Sewing machine – with zipper foot
• Serger
• Iron and ironing board

Cutting the Top and Bottom

Okay – first up we need to template the fabric with the pre-cut cushions. I do this by laying out all of my fabric in the basement, and I double it up since every boler cushion needs a top and a bottom. I don’t cut anything until everything is templated out.

I used chalk to template and add in 1/4 inch steam allowance to all sides.

Cutting the Sides

Don’t forget to measure the sides of the cushions. I don’t template these, but measure them out and ensure the corner seams are at logical spots. For the non-zipper sides I add the 1/4 inch to all sides. For the zipper section, I add in and additional 3/4 inches to the width to allow for the zipper seam. If you’re new to zippers, add 1 3/4 inches to give yourself room – but this will take more fabric.

You can see above that the piece to the far right is wider, that’ll be the long edge for the zipper.

Cut the zipper edge in half – lengthwise like a hotdog.

Sewing the Zipper

Now, time to make a zipper – I use the same zipper technique with pillows (but leave way more overhang). I’ll share in detail below, too.

1. Serge the two sides that you just cut to prevent fraying. DO NOT serge them together – not yet. You’re just serging the single edge.
2. Now, top stitch the right sides together about 1/4 inch from the edge.
3. Then, iron back the 1 inch over hang (right side down) and place the 18 inch zipper along the seam.
4. Ensure the zipper is centred and pin in place.
5. Now, top stitch all around the zipper using your zipper foot– be sure to indicate where the stopper is so you don’t break your needle. Sometimes I have to open the zipper to get around the pull.
6. Then, with a seam ripper, carefully rip open the initial top stitch you made to sew the two pieces together. Once you have it open you should see that you have a nice zipper nestled in the fabric.
7. Press and steam – the zipper side is done.

Want to watch me sew a zipper edge? Check out this post on Instagram!

Once the zippers are done, time to move on to sewing the cushion together.

Sewing the Cushion

First, serge all the side (the short ends) together – you’ll want to make sure that they’re not twisted and that they’re in the right order – right sides together. Then, press all the seams with your iron.

Once all of the sides are together, line up the top piece with the edges – right sides together. This is where you need a lot of pins. If your measurements are a bit off, you might have to spread out the gap/extra fabric to ensure it doesn’t bunch. I usually start pinning with about 12 inch gaps, and then come back and tighten up the pinning.

When all the pins are in place and the sides are inline with the top, serge away! Oh, and make sure you take the pins out.

Then, repeat the process with the bottom. Oh, make sure you open the zipper a bit so you can turn it right side out after you’re done pressing the seams.

Completed Cushions

Done! That’s it – it takes an unbelievable amount of time, but it’s worth the cute and cozy fabric, right? Check out these completed Boler cushions! I hope you had fun learning how to sew Boler trailer cushion covers.

Cushions in Action

Here are some cushions in action in some of our Boler trailers.

Well, there you have it – a lot of photos and a few tips and tricks on how to sew Boler trailer cushion covers. Thanks so much for stopping by and I’ll see you again soon!