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Poolside cushion made durable with Coats Outdoor Thread

Poolside cushion made durable with Coats Outdoor Thread

by Annette Millard

We could say that the first three patio cushions we reviewed this week have been more of a decorative purpose, and made using Coats Outdoor Thread they will be enjoyed for a long time.

Cushions are perfect for the pool deck, but can easily be adapted for patio seating. Coordinate the fabrics with your Outdoor Cushions for a “hired a decorator” upscale look for your outdoor space. For versatility, make the top and bottom in different prints so you can switch up the look from time to time. When you purchase foam for your cushions, you may want to mention that it will be used outside in case there’s a weather-resistant foam available. Keeping these tips in mind, these poolside cushion will be very durable in all summer weather using Coats Outdoor Thread!

Poolside cushions are comfortable for patio furniture and durable when made with Coats Outdoor Thread

Poolside cushions are comfortable for patio furniture

Here are some tips when using Coats Outdoor thread

  1. Use a size 18 or 20 (110 or 120) needle. A topstitching needle is recommended because it has a larger eye.
  2. Use a longer stitch length, 6-8 stitches per 1″ [4mm]. A thick thread needs more space to form a stitch
  3. If you’re getting loops on the underside, increase your upper tension.
  4. Sew slowly. The thread is not as flexible as all-purpose thread, so reducing your speed results in better stitch formation.

200yd spool of Coats Outdoor Thread in blue used particularly for making patio furniture and accessories

200yd spool of Coats Outdoor Thread in blue

skill level intermediate

finished measurements approximately 20″ [51cm] squared x 3″ [7.5cm] thick


To make one cushion

Coats Outdoor Thread

Outdoor fabric, 44 – 54″ [112 – 137cm] wide:

* ¾yd [68cm] print fabric- cushion base

* ⅜yd [34.5cm] solid fabric for boxing strip

* ⅛yd [11.5cm] solid color fabric for handle

Foam rubber, 20″ [51cm] squared x 3″ [7.5cm] thick

Plastic wrap or a large plastic dry-cleaner bag




  1. Base – 21″ [53.3cm] square of print fabric. Cut 2.
  2. Boxing – 4”+ x 41” [10.3 + x 104cm] strip solid fabric. Cut 2. (+ or 1” [2.54cm] wider than foam)
  3. Handle – 4” x 9” [10.3 x 23cm] rectangle of solid fabric.


Mark a 20″ [51cm] square on foam. Hold foam on its edge and use a sawing motion to cut along the markings with a sharp serrated steak knife or electric knife.


boxing strip

  1. On right side of both boxing strips, mark a dot at pillow corners as Diagram 1. Also mark center of each boxing strip. Mark lines for handle placement 3” [7.5cm] on either side of center.
  1. Reinforce corners by stay-stitching just inside the ½″ [1.2cm] seam allowance, about an inch to each side of each dot. Clip the fabric up-to, but not-through the stay-stitching. Place ends of boxing strips, right sides together. Stitch across end, creating a continuous circle.

Diagram 1

Diagram 1


  1. Right sides together, fold the handle in half lengthwise and pin. Sew across each short end and long edge, leaving an opening for turning. Trim seams and clip corners. Turn and press. Top stitch ⅛″ along edges of handle.

Pin short ends at handle markings. Stitch handle to boxing strip as in Diagram 2.

Diagram 2

Diagram 2

joining boxing to base

  1. Mark center of each side of pillow base.
  1. With right sides together and cut edges even, pin boxing strip to one cushion base, matching first each center and seam of strip to each center of base, then matching each clipped corner of strip to each corner of base. Pin every 1½″ – 2″ [3.7 – 5cm].
  1. Sew strip to base, pivoting at corners. Sew remaining cushion base to the other side of the boxing, leaving an 18″ opening centered along one edge. Press and trim seams, clip corners and turn to right side through opening.

Diagram 3

Diagram 3

Wrap foam with plastic bag and slip into pillow cover. Reach inside cover and remove plastic. Slip stitch opening closed.

faux piping

With a hand needle and using a basting stitch, sew ½″ [1.2cm] from seam line on both the base side and boxing strip side of the cover.

Diagram 4

Diagram 4

Tomorrow, we make a cubed cushion for more poolside fun using Coats Outdoor Threads.

This is part 4 of 5 in this series.
Go back to part 3:  Making patio cushions require Coats Outdoor Thread for longevity

Go to part 5: Making a cubed cushion for poolside decor using Coats Outdoor Thread

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Lori Smanski March 8, 2017 - 10:21 pm

what a great tutorial. thanks for the tips

Wehaf March 8, 2017 - 9:29 am

I’ve always steered away from making any outdoor cushions but I think now I am ready to give one a try! Porch swing pillow, here we come!

Diane Beck March 6, 2017 - 5:22 am

I have wanted to make a cushion for a front porch swing. Thanks for the great info!

Lori Morton March 5, 2017 - 9:52 pm

Thank you for how to make these cushions!! Want to make some for our front porch!! 🙂

MoeWest March 5, 2017 - 9:11 pm

I used this thread when I made new outdoor cushions two years ago. I like it and it has held up well.


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