Custom Upholstery

By Frank Parker

This custom-made dining lounge was designed and manufactured by a cabinet making firm then upholstered by a local upholstery business. The frame was well designed and constructed however there were continual substantial issues with the upholstery. Unfortunately this is something that occurs to often in our industry. 

A client approached us saying she had a custom-made dining lounge and there were substantial issues with the upholstery and she had given up trying to negotiate any solution with this upholstery business. The entire front edge of the seat had collapsed and buttons which she did not want but were initiated by the upholstery firm had ‘popped’. Our client engaged us to completely re-upholster this dining lounge.

We completely removed the existing upholstery and discovered the problems causing the clients concerns. The previous upholsterers had used high quality foam on the seat however they had used a water based contact adhesive to which there are still major application problems and is was simply just not effective. Also the reason they had to place buttons into the seat and back panels was that the patterns were not true to the frame sizes causing the cushions to distort.

We started from scratch making templates true to the frame then fabricated premium cushioning and laminated it with bonded polyester fibre. The cushion covers were then carefully marked with sewing indicators and sewn to shape as such large panels can either be stretched or gathered. The lounge was then upholstered with minimal effort as the fabric covers fitted perfectly.

The result was that our client was absolutely overwhelmed with the result and we have since received repeat work from her. This just goes to show that quality work is always the best form of advertising and everyone is a winner.

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    Oliver’s Upholstery was founded by Andrew Oliver in the late 1980’s being situated in Perth Western Australia. The business manufactured economically priced upholstered furniture for the WA retail sector. The business grew quickly becoming one of the larger upholstery manufacturers by volume in the State. However about a decade of operation cheap inferior products started coming into Australia from Malaysia and Thailand then flooding in from China.

    With the value area of the local market being displaced with imported furniture Andrew Oliver changed directions renaming the business Oliver’s Re-upholstery focusing on re-upholstery and commercial upholstery.

    Long term clients approached us when renovating their home wanting to have two wing back chairs re-upholstered. These clients resided in a leafy Perth suburb and thought the chairs were rather special but it’s difficult to explain to such clients that their taste in furniture maybe a bit ordinary, especially if they want the chairs re-upholstered in a high quality leather.

    The upholstery was rather tacky so we stripped the chairs back to the bare frames and were rather surprised that the frames were soundly constructed. We sprung the frames, laminated the body work with high density foam padding slightly redesigning the upholstery. The leather was a full-aniline leather from Tasman Tanning and was a pleasure to use as the chairs took shape. Using more traditional labour intensive upholstery techniques paid off as displayed by the finished product.

    Our clients were simply “gob-smacked” with their re-upholstered wing back chairs which just goes to show that you can make a silk purse from a sow’s ear!

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  • Why do modern sprung cushions have problems?

    cushion upholstery Perth

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    Contemporary sprung cushions have been marketed over the last decade as a superior concept however there are major issues regarding the effectiveness of using ‘spring pockets’ in the fabrication of seat cushion inserts.

    How are traditional spring cushions different to modern spring cushions?

    Traditional sprung cushions were constructed using mid-gauge coil springs and hand sewn into a hessian case then encased with flock and fitted into a box piped seat cushion with sewing usually finished by hand stitching. Seat cushions constructed this way tend to stand the test of time as is evident by cushions still used in antique furniture.

    However the fabrication of modern sprung cushion inserts utilise light-gauge coil springs encased in a series of thin polyester pockets which are normally referred to as ‘spring pockets’. These spring pockets are placed in the centre of the cushion inserts and sandwiched with polyurethane foam then usually encased with polyester fibre. With moderate to heavy use the spring pockets tend to distort with the springs often fracturing the casings. The result is a distorted and uncomfortable seat cushion and maybe a costly repair bill outside the warranty period.

    What about the option of premium quality foam cushions?

    The sales personnel promoting the “advantages” of sprung cushions usually infer by definition that the base is also sprung but most sprung cushions are on bases fitted with elastic webbing. The truth is that there is nothing wrong with a settee base correctly fitted with high quality elastic webbing. However a superior cushion insert can be effectively achieved by simply using premium quality polyurethane foam encased in polyester fibre and no spring pockets!

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  • Re-styled 1940’s chairs

    Occasionally clients are unhappy with the style of the chairs presented to us for repair and re-upholstery. This can be as a result of either initial design flaws, poor re-upholstery or poor reconstruction as a result of previous damage or sometimes a combination of these factors. The idea is not necessarily to bring a chair back its purest original form but occasionally compromise with slight re-styling to compliment the client’s décor.

    These two 1940’s chairs were presented to us by a client as they had been passed down to her through the family. She wanted the chairs to be re-upholstered however she wanted the arms modified on one chair and the wings to be altered on the other chair. This re-styling was required partially due to initial design flaws but also due to past re-upholstery exaggerating these flaws.

    We completely stripped the existing upholstery on both chairs down to the bare frames. The top arms on one chair were then cut down to a cigar shaped arm in keeping with the design while the other chair had a plywood strip removed from the inside wings which improvised as a thumb roll. The two modified chair frames were then re-upholstered using a combination of traditional and contemporary methods.

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    The History of Thomas Howard Brown

    Thomas Howard Brown formed T.H Brown during 1911 in Adelaide. The brand became a household name in furniture during the first half of the 20th century being one of Australia’s largest furniture manufacturers by the 1920’s and producing its two millionth chair by the 1940’s.

    Thomas’s son Peter joined the business after his return from WWII and went on to develop some of T.H. Brown’s most iconic pieces of furniture. Peter and his brother Napier ran the business until 1987 when T.H. Brown was sold to Work Space Commercial Furniture.

    Thomas’s grandson Simon joined the business in 2015 and formed a joint operation to re-launch some of T.H. Brown’s mid-century signature pieces.

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    Our client has a classic mid-century home and wished to furnish it appropriately. She had acquired a substantial range of pre-loved furniture from this era over several years and we were fortunate in been given the task of restoring these pieces.

    The Reupholstery Process We Undertook

    One of our tasks was to restore a set of six T.H. Brown dining chairs.

    • We carefully stripped these chairs down
    • Due to the quality of construction few repairs were required
    • The chairs were then carefully sanded back
    • Three coats of clear lacquer were applied being sanded back between coats
    • The frames were then gently rubbed back with super fine steel wool to enhance the matt finish required
    • We then laminated the seat ply panel with high density premium padding and
    • Upholstered the seat with a classic mid-century textured velvet.

    This beautiful mid-century furniture was completely rejuvenated to its bygone glory days and our client is now living out her dream.

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  • Re-upholster Antique Chairs

    Occasionally we receive antique chairs which are basically well preserved but they have been previously shabbily re-upholstered or upholstered out of context with the era. This rarely does the furniture justice and usually results in complete restoration.

    Our client came to us with a lounge chair made in the 1890’s having been originally purchased by her deceased husband’s grandparents. She was honest in explaining that under her instructions the chair had been re-upholstered in the early 1980’s in a pastel cotton and the style modernised to match their décor at a previous residence. She was now ashamed of her previous decision and wanted the chair re-upholstered to its previous glory.

    The chair’s design had been modernised by having a loose seat cushion fitted and absence of piped detail. We removed all the upholstery stripping the chair down to the bare frame and the turned timber legs were then cleaned and polished. Heavy weight jute webbing was then fitted to the seat and back, the coil springs laced, tied down then hessian overlays fitted. We used synthetic ‘thumb roll’ on the seat front, arms and back scrolls then laminated premium polyurethane foams finished with polyester overlays. The seat cushion inner was fabricated from high resilience foam and encased with bonded polyester fibre.

    The chair was then upholstered using a fabric selected by our client which suited the chair and was basically in keeping with the period. The result was a chair which was modernised to a degree under the cover for comfort however retained much authenticity with the upholstery finish and piped detail. Our client was over joyed with her chair and no doubt will become a family heirloom.

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  • Re-upholstery of a Jason Recliner Chair

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    Transforming the Classic Jason Recliner

    Jason recliner chairs are an iconic piece of Australian furniture valued for their quality craftsmanship and durability, making them sought after to this day. This restoration aimed to preserve the chair’s structure for future generations to come.

    The Origin of Jason Recliners

    Jason chairs were manufactured under license from Lazy Boy in Munro Michigan. The factory operated in Welshpool WA from the mid 1960s through to about 1990. These chairs were known for featuring a very robust and unique mechanism. The business was owned and managed by the Bridge family with the chairs distributed around Australia and at its peak they were also exported.

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    • The chair was completely stripped and the mechanism cleaned and lubricated
    • The show-wood rocker base and the turned wing sections were sanded and re-lacquered dark walnut
    • The back zig zag springs were linked
    • New hessian was layered over the seat springs
    • New high density padding was laminated onto the body
    • New polyester encased premium cushioning was fabricated and
    • The chair was then re-upholstered to the same finish in an English Heritage Linen
    This chair was also of sentimental value as it previously belonged to our client’s father. We wish her many years of memorable moments in this special chair.
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