DIY Envelope Box Cushion Covers

Looking for a DIY Envelope Box Cushion Covers tutorial?  

Look no further.  I have you “covered!”  (couldn’t resist)

You see, a few years back, we got this sectional outdoor couch, of sorts, to use on our screened porch:

As you can see from the photo above, the cushions it came with had white, zippered covers.  They weren’t terrible, but I removed them at the end of the summer to launder, and they started to fall apart.

Zippers began to break, fabric began to fray.  The covers showed discoloration and staining that increasingly went from unattractive to downright gross!

I first searched for replacement cushion covers, but could not find any that were the correct sizes.

Next, I searched for instructions on how to make covers for this type of cushion but without a zipper.

I couldn’t find any such thing.  They either had zippers, or the cushion cover instructions I found were for regular, old throw pillows.

For my version of square pillow covers see blog post HERE.

I searched high and low and could not find a tutorial for any DIY envelope box cushion covers for the life of me.  The tutorials I found all had zippers.

While I have nothing against zippers, I was looking for an easier way to construct and use these covers.  Zippers can sometimes be a pain.

So…I found that if I use the same basic idea for the pillow cover, I could create a similar cover for the box cushion.

I just had to make a couple of modifications.

Since a box cushion has, essentially, four more pieces(than a regular cushion) going around the outside edges, it was necessary to extend the overlap.  Here is what I mean:

I recommend using durable, washable fabric.  This way you won’t have to make new covers very often. 

I also recommend using a neutral fabric and jazzing up your color scheme with the smaller, simpler, pillow covers.

Let’s get started!

Fabric (As stated above, I prefer machine-washable fabrics) 

Paper to make patterns(I recommend clean craft paper or packing paper.  Newsprint can get messy and make your fabric dirty.  You could also use special material for patterns.  Ask at your local fabric or craft store.)

Thread

Sewing machine

Scissors

Tape measure or yardstick

Cushion (or cushion insert)

DIY Envelope Box Cushion Covers 

You will need to measure your cushion.  

My cushion is a rectangle measuring    17″ by 34″, with a 3″ wide “gusset.”(17″ x 34″ x 3”)

I will cut a few pieces of fabric per cushion.  The math to figure out the sizes is as follows:

The large side of the cushion is  17  inches by 34″ inches (rectangle).

Add one inch to each of the box cushion’s large side measurements, for example, if your pillow is ” by “, you will add 1 inch to both of the sides making it 18″ by  35”.

For the other large side, the width will be calculated the same way, but  figure that the length (34″) will add 6 inches. 

So for a 17″ by 34″ pillow, you’d do this equation:  17″ + 1″ = 18″ by 34″+ 6″ = 40″

Your final cut piece of fabric for the second large side should measure 18″ by 40″.

My gussets are 3″ wide, and I will need 4 altogether – 2 short and 2 long.

I will cut 2 gusset pieces to measure 3″ + 1″ = 4″ wide by 17″ + 1″ = 18″ long.

Then I will cut 1 gusset piece to measure 3″ + 1″ = 4″ wide by 34″ + 1″ = 35″long.

The last gusset piece will measure 3″ + 1″ = 4″ wide by 34″ + 6″ 40″ long.

Doing the Math – Large Pieces

Here is the math to use for any size rectangular box pillow cushion cover:

The pillow is “X”  inches(short side) by “Y” inches(long side) by “Z” inches(gusset).

**Remember that we will be stitching a 1/2″ seam allowance on all seams.

1. One piece you will cut for the cover will be X + 1 inches by Y + 1 inches.

2. The second piece you will cut will be as follows:

The short side of the fabric will measure:  X + 1 inches.

The other side of the fabric will measure: Y + 6 inches.

The gussets will all be the same width, “Z”, by different lengths.

Each gusset will measure either Z by X or Z by Y.  You will have to add 1 inch to each side for a half-inch seam allowance all the way around as follows:

3 & 4. Cut 2 = Z + 1″ by X + 1″

5. Cut 1 =  Z+ 1″ by Y+1″

One of the “Y” length gussets will have to work the same way as the long side you add 6 inches to:

6. Y + 6 inches by Z + 1 inch (Cut one piece)

You should now have 6 pieces.

Cutting Tips

When cutting a raw edge so that it is straight, use a T-square, yardstick, or other straight-edged tool.

If you have a cutting mat that has the measurements pre-printed on it, that can work, too.

If you are using a fabric with a straight-line pattern, such as ticking or gingham checks, cut straight along one of the lines that correspond with your fabric measurement. (Be sure to get extra fabric if you are trying to match up a fabric pattern!)

Double-Check

Here is another easy trick if buying new fabric – bring your cushion with you to the store.  Hold it up to the fabric and unwrap some of the material from the bolt to see if it will be an appropriate measurement. 

You still need to have accurate measurements, but this is still a good way to double-check that you’re on the right track with buying enough fabric.

And even then, I add 1/4 – 1/2 yard extra!

Once we’ve determined how much fabric we’ll need, we’ll have it measured and cut.  Then we’ll pick out a matching thread!

Sew the DIY Box Cushion Covers Step-by-Step

1. If you haven’t already, measure and cut out your six pieces of fabric as per the above instructions.  If you need to, cut a pattern first.

2. Take your extra long pieces – the (X + 1 by Y + 6) and the (Z + 1 by Y + 6).

Pin (baste if you like) the right sides together along Y + 6 edges.  Stitch.

3. Cut this newly-sewn piece down the middle, right through your stitching, so that you will now have 2 pieces that each measure (X + Z + 1) by (1/2 Y + 3)

4. Narrow hem each of the edges you just cut. They will ultimately overlap.  I would turn the edges under twice for a nice, clean finish.

For my cushion cover, this worked as follows:

I took the piece of fabric measuring 18″ x 40″ and stitched it along the 40″ side (right sides together) to the 40″ side of the gusset piece measuring 4″ x 40″.  Now my sewn fabric measures 21″ x 40″.  (If you think this does not add up correctly because 18 + 4 = 22, remember that when we stitch them together using a half-inch seam allowance, that removes an inch from the total measurement.)

Then, I cut this piece in half to create two pieces measuring 21″ by 20″ each.

After hemming each of the inner, overlapping edges, set these two pieces aside.

5. Take the remaining 3 gusset pieces and stitch the two shorter pieces to each end of the longer piece, right sides together. 

6. Next, take the large piece that is left (this will be either the front or top of your cushion cover), and pin it, right sides together, to the gusset pieces you just stitched.  Match the seams to the corners of the large rectangular piece.  Pin. (baste if you like)

7. Stitch into place.

When turned right side out, the corners should look like this:

8. Now comes the slightly tricky part.  You will need to take the two pieces you set aside, match the up, and pin the raw edges accordingly:

Do you see the overlap in the middle?  Make sure all of the edges line up correctly when you pin these pieces in place, right sides together.

Here is an up-close view of what it looks like to stitch one of the corners:

Do you see how the little seam at the end of the gusset is split so that each side can line up flush with the other piece of fabric?  It makes for a nice-looking finished corner.

9. After stitching the last of the raw edges all the way around, turn the box cushion cover right side out.  

If it makes sense to clip the corners first, do so carefully.  I found that this was not necessary in all cases.

10. Now it’s time to cover the cushions with the DIY Box Cushion Covers!

For another view:

What do you think?  

Is this something you’d like to try?

If you make them, I’d love to know how they turn out!  Please let me know!

Blessings,

Wendy

🩷