Marshal Spring System - cotton batting lumpy
Hello, Joe! (i tried posting this before, but it gave me an error. Just delete this, if it happens to show up).
Thanks for creating this forum! I'm excited to read up on blog posts and dig through the forum for future projects.
I recently took my antique sofa down to the bones, replaced springs, batting, etc. My issue is with the cushion. I turned my 3 cushion into a single, replaced the coil system, wrapped it in what seems like one hundred layers of batting. First movie night...butt divot on my husband's side (he weights about 167 lbs). My side stayed firm longer, but ended up seeing signs of wear. I reopened the inner cushion cover, added more cotton batting, placed 1 inch HD foam, and another layer of cotton batting. I didn't stuff it back in the outer cover before I tested another movie night....Another butt divot! my beautiful cushion looks like a fun house mirror.
My questions are, 1). Should I open her back up and replace the cotton batting with HD foam and wrap that in cotton batting? 2). If so, how thick should the HD foam be, and what density?
I appreciate your insight, and am excited to have a nicely filled out sofa cushion!
Also, I attached a photo of the cushion at it's not best, but not worst condition. Before the last stuffing, it was much, MUCH worse.
Jack of all trades. Master of none.
Making a cushion with marshal units and cotton batting can be tricky. So tricky, I don't even make them myself. I always send them out to my cushion fabricator Albany Foam and Supply in NY. One issue may be the gauge of the springs in the marshal unit. A firm marshal unit for a seat would be around 13 gauge. A soft marshal unit for a back would be around 16 gauge. If you used a soft marshal unit meant for back cushions, this could explain the divots.
A few things:
1) If you were to use foam, the thickness of the foam depends on the finished height of you cushion boxing. For example, if your finished boxing was 3 1/4", I would recommend using 4" foam wrapped in one or two layers of dacron batting. I would not use cotton batting, especially over foam. There are different types of dacron batting as well, bonded and stitched. If you tell me the height of your cushion boxing I can help with the foam thickness and dacron wrap.
2) Generally for seat foam, I use a medium compression. The specifications would be 2.6 density with a medium compression of 35 lbs. So when I buy the foam, the specification would be a 2635 foam.
3) As to your photo, thanks for including it. Is it an optical illusion or does the front of your seat decking rise in the middle.
Hi Joe! Thanks for getting back with me! I double checked the innersprings I ordered and they are too short. I think I got overwhelmed with all the info I was looking through and ordered the wrong thing. Since my old springs are still in good condition, I shot some compressed air through them to blow out the antique farts, rewrapped them in batting, and it seams to be what was the issue.
Thanks again for the tips!!
Jack of all trades. Master of none.
Thanks for the update. Wrong spring height makes sense. Wish I thought of that. I was close with the spring gauge 🙂
It's to late to mention this now since you are finished, but when my cushion fabricator makes a spring cushion, the marshal units are covered in muslin. The muslin helps prevent the batting from falling into the springs. Then the marshal unit is encased top, bottom and all sides with 1" foam. Then the batting, then a down proof ticking cover.