- 1). Cut two 18-inch squares from the 6-inch thick foam. Also cut a rectangle 18 by 20 inches and two additional rectangles that are 18 by 24 inches. It is easier to cut foam with a sharp, non-serrated knife than with a scissor. These measurements can be adjusted depending on the size chair you wish to make.
- 2). Use the foam chair pieces as templates to trace the required measurements onto the back of the sturdy fabric you chose. Cut a piece of fabric for the front and back of each rectangle as well as a long, continuous strip for the sides. The two 18-inch squares will be stacked for the base of the chair. They only need one front and back and a wider strip to go around both of them together. Remember to add an extra half to whole inch to each piece for sewing.
- 3). Thread the sewing machine with a sturdy thread that matches the color of the fabric. Lay each top piece of fabric, good side up, on a flat surface and lay the strips of fabric that will go around the foam, good side down, on top of them. Pin together with straight pins if desired. Sew them together using the sewing machine and repeat the process for the bottom piece of fabric. Leave one side of each fabric sleeve open to put the foam cushions in. Turn right side out.
- 4). Squeeze the foam pieces into the fabric covers you have sewn. Make sure they sit straight and fill out the entire sleeve completely. Close the final sides of the fabric by turning under the raw edges and stitching the edges together with a needle and strong thread.
- 5). Place the 12-inch-tall rectangle on a flat surface. This will be the seat of the chair. Cover the back edge of it liberally with glue from the hot glue gun and press on the bottom of the 20-inch-tall foam rectangle. Glue each 18-by-24-inch rectangle to a side of the foam base and back to create the arms of the chair. For added sturdiness, use a needle and thread to sew the pieces together by their fabric edges.
Make a Foam Toddler Chair
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