Endeavour Cushions
Date: March 22, 1999 Thought I would pass this along as some helpful info. I just recently redid all my cushions inside and out. I contacted JSI in Florida 1-800-652-4914 and dealt with Steve Meadows. He is very helpful and has many of the patterns for the Endeavours. They made the original cushion sets for Endeavour beginning in the 80's. NOTE: JSI (now SailNet) made the cushions (and therefore has the templates) for Endeavour boats built from 1985 thru 1990. This included the E33 and E35. They also did some E38cc, E42, and E51 by hull number. While JSI didn't have a contract to do the earlier boats, they do have SOME of the templates for them. It should also be noted that it's not that hard to make the templates (they have on-line directions). Paul Uhl endvr32@endeavourowners.com Date: September 2, 1999 I was wondering if anybody had recently made new cushions for their Endeavour and could relate their experience(s). My wife Barb knows her way around a sewing machine quite well and we're considering redoing all of the cushions ourselves. I would be very appreciative to hear from owners about fabric the selecetions you've made, patterns if you've done the cushions yourself, and selection of foam. Also did you change the cushion style and what forms of attachment did you use. Date: September 2, 1999 Hi, Just redid all the cushions on my 38 centercockpit. What I did was to take the old cushions and take the covers apart and used them for a pattern. I traced the old pattern onto the new material.I added cording around the edges for looks but not necessary. Then just sew them up..I did take the old cushions to a bedding factory, and had them cut out new foam in the exact shape as the old ones, they had absorbed so much oil smell over the years couldn't stand it! LOL I did save the zippers from the old cushions and just use them as they are expensive and they were plastic and worked just fine. As long as your machine can handle heavier fabrics probably no special attachments will be needed.., just your zipper foot, etc..etc... I did use upholstery thread for strength, and an upholstery needle. Hope this helps..email me if I can give any other suggestion. Oh, I did spray the material, with a water repellent, scotch guard when I was done. helps with stains and moisture. Date: September 2, 1999 Which Endeavour? I just had all the cushions on my 37 A-plan redone in Trinidad (very economical)...changed the style and attachment...etc, also new foam...Websters did the whole job for $400...we went to Velcro attachment, a nice blue velour with plastic zippers that is machine washable (the dog sometimes sleeps on the settee) Date: September 2, 1999 The Previous owner of my '78 E32 "Destiny" had all the cushions on board replaced. He was a big man so he replaced all cushions with 5" foam. The foam is firm enough so that my wife and I sleep in the bow and never touch bottom. Its very comfortable. I suggest you consider the same. The only problem we've noticed is the little board to fill the v birth hole seems a little more difficult to align in place. It's really not a problem just an annoyance. Date: September 2, 1999 My wife and I changed the cushions on our E-42 several years ago. We called JSI (now called SailNet) in St. Petersburg, Florida. They made the original cushions for Endeavour and have all of the patterns. They asked us for year of boat manufacture and hull number and they then made us PERFECT fitting cushions...JSI (800) 234-3220 Date: September 2, 1999 The dpo made up new cushions and used "textilene" [sp?] fabric. They won't mildew, they're easy to clean, and are practically indestructable, but....... they are very *firm* and the 2 inch foam he used as a cushion is not comfortable after a couple of hours.... and even less so if you (as we often do in the tropics) like to sleep in the cockpit. We bought some sport seats from West Marine...essentially they are a small chaise lounge without the legs, covered with "sunbrella" as cockpit seats... VERY comfortable for sitting upright or lounging. They are absolutely the single best purchase we've made for the boat !! We've taken a piece of "egg carton" convoluted foam mattress pad to cover the cushions when we sleep on deck. If I were doing it again, I'd go with 'at least' 3 inches of a medium firm foam rubber, keep using textilene for the covers, and have the "seamstress" make up some 200 thread count sheet slip covers that allow space for the convoluted foam for nighttime use. Date: September 2, 1999 I had a very similar experience as Josh with JSI a couple of years ago, the fit was excellent. Date: September 2, 1999 I haven't had any direct experience with new cushions, but the previous owner had new cushions made shortly before we bought the boat. The fabric used was a green (Erin) Sunbrella, same as the sail cover, etc. We think it is great. Wears well, cool to sit on, easy to wash and doesn't seem to shrink.. Cushions were held to settees with contact glue backed velcro. This didn't work well. The starboard cushion would slide to the floor on a starboard tack and when you came about the port cushion would join it. I had a fabric strip sewn into the lower seam at each end of each "seat" cushion, with a snap and corresponding snap screwed into the fiberglass of the bunk. Now they stay put but it is very easy to unsnap them if they need to be removed for some reason. Date: September 2, 1999 I'm just finishing all new cushions. I used the old foam as templates and replaced the foam with foam the same density and thickness - they probably got it right the first time, so why tinker with it? I bought a good quality upholstery fabric at a local fabric shop. Used upholstery thread. Easy to sew and came out just fine, if I do say so myself. I'm no whiz as a seamstress, so if I can do it, most anyone can. I figure I saved around $600 or so dollars, maybe more. Date: September 3, 1999 Lois, Ours really need to be done--they're turning to dust! Date: September 3, 1999 On the C27 we used white vinyl on the bottoms and backs of the cushions so they would be easier to clean, but I think I'll skip the vinyl when we recover the cushions on the Endeavour Date: September 4, 1999 A.C., Date: September 4, 1999 I'm not sure if you are talking about the interior of exterior cushions. I'll reply to both. First, we replaced our interior cushions 8 years ago and they still look great. Foam and Fabric are key, don't scrimp. Our main salon was done for about $400 (1991 $'s). We changes the method siginificantly and are pleased with the out come. Most E-40's had a continous lower seat cushion with 5 small back and side cushions held by teak knobs, and an additional long cushion for when the setee is pulled out for sleeping. We replaced that arrangement by removing the teak knobs, installing single 1 inch sticky back velcro strip across the back, bottom and side's. We replaced the three back cushions with one long one of equal thickness as the bottom cushion. In doing this we eliminated the need to carry the "sleeping cushions" as we pull out the sliding section of the setee and the back cushion works perfectly with the other bottom cushion as a double bunk. We had new end cushions made as we found we lean alot. I scotch-guard (tm) the cushions about once every two years. Keep the kids with wet trunks off the and they will last. The other cushions such as the angle seats were also redone in the same material. The aft bed was replaced about 3 years ago, no special fabric on it butit was custom sized. On exterior cushions, I copied Zeek's helm chair so we no longer use the long narrow cushion in the back. We are currently in the process of sewing sumbrella (white with blue piping) cover's for single piece cushions made from 2 and 1/2 inch closed cell "sea foam" tm. which we purchased for Defender a couple of years ago. I hope this helps. Date: September 6, 1999 JSI in clearwater,Fl has spec for most indeavour cushions. Date: September 7, 1999 Jack, Date: September 7, 1999 Hi Paul, I know that you have a 32 and as such cannot offer any specific suggestions for attachment or where to put the splits etc. Judy says she will go the full cloth cushions again rather than vinyl backed when she replaces ours, which will be this winter season. Maybe we can work out a deal with your "great sewer-Barb". We don't know the thickness of your foam (ours is 5") but if yours is thin or broken down then obviously now would be the time to replace it. My selection would be for a very dense foam with a minumum of 4". I can contact the place we used to get the name of the foam if you would like. My only advise on cloth selection would be to take a swatch, put on a pair of shorts (swimming suit ?) and sit on it, with your skin on whatever the material is to see if it itchs scratchs etc etc... Then of course there is always lying down in the altogether when the temps get in the 100 range (muggy of course), whatever comes to mind (!) :-) and you are lying in a pool of sweat because the material can't breath. We will probably go a regular upolstery with a nylon base, "Olefin" (spell ?) comes to mind. I and many friends have used Johnson Sails (JSI) out of Florida for cushions, sail work, and bimini/dodgers in the past, and have liked the results, but it does get costly. JSI does have a web page. The reason that I bring this up is that they have a great measuring package and great instructions on how to measure. They will also send out a very complete set of material swatchs (with a charge, refundable on return). Date: September 7, 1999 Carl, I spoke with Steve Meadows who seems very knowledgable about Endeavours in general, and he indicated the following for cushions: 1.5lb foam = entry (ie: cheap) level My impression was that for day sailing and the occasional 2-week summer vacation, the 1.8lb foam would last about 10 years. Liveaboard quality should be atleast 2.3lb. He recommends the following fabrics: nylon, olifon, polyester, and acrylic. They work with 54" wide fabric and can supply either a split or full width v-berth cushion--he recommends the full width because the forward 'point' on the split cushion tends to otherwise curl and bend. He seemed to think that Velcro attachments work well, and was an improvement over the 'knob' approach Endeavour used to hang many of the seat backs. He was also willing to accept fabric supplied by us. Also, when I told him that we had recently been to a boat show and saw something we liked, he said he could probably get it for us. Date: September 7, 1999 Sorry I did not reply sooner..*Went Sailing!* (grin) I would suggest you take the original ones to the bedding factory and let them cut the foam from them, especially if you plan on using the original covers as the pattern..We have a 38ft center cockpit with the two side salon cushions and backs. The reason I suggest using the original covers, and taking the cushions (old ones) to have them cut is because of a slight angle cut in the salon cushions. It's important that you get this cut just right, and if you use the original covers as the pattern it will fit better. Your choice of foam will be up to you, as they have several different ones to choose from. We got a rather dense firm foam mainly to maintain the shape. I used, believe it or not a plaid and matching stripe upholstery material, not sure that I would recommend that as a choice, unless you like matching stripes. LOL I am sure your wife will understand what I am referring too, but I liked it. Its hunter green, maroon and navy blue. Our boat is all white with hunter green accents, like sail covers etc. We also did the v-berth and aft-berth cushions too, that is why I suggested the bedding factory because the v-Berth cushions are such a crazy shape. They say you can cut the foam yourself using an electric knife but I didn't want to mess with that. We put a metal loop behind the back cushons and just wrap a bungie cord around it to hold it in place when sailing. My *hubby* also ran a small piece of wood along the part you sit on to form a small ledge which keeps the cushion you sit on from sliding about when sailing...works pretty good. I still have to recover the seat under the Navigators table, but that shouldn't be too hard, again I plan on using the original for the pattern. Well I hope this helps. It really is not that difficult--just takes time. Not sure if I mentioned it before but save the zippers from the old covers, unless they just don't work. OK saves a lot of bucks as they are expensive. OH, one thing about the foam. You buy it in blocks, that is why you should take the original cushions with you. That way they can lay it on top of just the size you will need rather then guessing and wasting a lot of foam..OK Let me know if this helps or if I can help anymore.. Date: September 16, 199 We've just replaced our cockpit cushions after much discussion if the ones that came with the boat could really have been original equipment..awful things- about 1" thick, white naugahide and ill fitting. Anyway we chose a Sunbrella fabric in Fawn (the color of muddobber droppings and sandwich crumbs- as light as we felt we could go without some of the solar gain and fading problems inherent with the darker hues) in a 3" dense waterproof foam that a canvas man at our marina made. This was the thickest we could use and still have full use of the combing boxes just behind the traveller as it ends up 2 1/2" thick when it is "drawn" down tight. We designed them in 5 sections: a full one across the lazarette box area, long ones on the sides that break on both sides in line with the starboard ice chest which has it's own (almost square) cushion that is handy to remove for access to drinks and held aside from boarding with street shoes with a matching small one on the port side both of which fit up to the traveller. Jack did a great job on fitting them the way we wanted them with zippers and Scotchguarded them too. They cost us $550.00 The cabin and V-berth cushions were just redone when we bought the boat last summer in a cushy foam covered with marine damask in a subtile teal/ taupe palm leaf pattern that oddly seems to work with the vintage gold "leatherette" Formica on the table and galley work surface. We also put in new carpeting (somehow we aren't blessed with the teak and holly that I've read was supposed to be the standard issue sole) that is a trendy new gold sisal look. The extra throw pillows are in Caribbean lime, blue and yellow with some pink... it's kinda fun. The best part is the zippered screen over the companionway that keeps the mosquitoes out when we're spending the night and does a teriffic job of holding the muddobbers back when the boat is closed up! It's got a snap on Sunbrella edge that was fit to the whole "L" shaped opening with loose weave synthetic fabric that unzips three ways. Half rolls up tight against the bulkhead with velcro and the other half in front of the steps above the master control panel. Date: September 25, 1999 The boat in the slip next to us is a Sabre 34. The owner got quotes for new cushions for his boat that ranged up to $4,500. He chose to buy his fabric on sale. He bought his own 5" thick upholstery grade foam wholesale from an upholstery supplier which he cut to size himself using the old cushions as patterns. Importantly, he purchased different density foam for his cushions, bunks and seat-backs based upon the recommendations of his supplier. He then transported the foam and fabric to a Chicago upholsterer that works out of his home. His total cost for new cushions throughout his boat amounted to about $1,000. A lot of monkey business on his part but he earned several hundred dollars per hour for his efforts. The end result was superb! Date: September 26, 1999 One thing I've heard about using the old cushion foam as a template is that the original shape can become distorted over time. However, if you use a clothes/fabric steamer on the old foam it will apparently come back to it's original shape. Date: September 30, 1999 My wife is a seamstress and earns a pretty good buck doing just what you folks have been doing. The advice here is right on for a do it yourselfer. She just finished doing all of our interior cushions today and we just got back from putting them on the boat. Beautiful! She used a very high quality brushed cotton fabric. It is very durable, soft to the touch and comes in many beautiful patterns. (ours is a print of old world maps, very nautical, colors are blue, burgandy, yellow, gold, green, navy, brown, cream.....it all goes very nicely with the wood interior of our boat. She used a very high quality white vinynl for the bottoms. The fabric comes with a soil retardant in it but we also added to that with a spray application. To refresh the foam if it is still in good condition, you steam it with a steam iron. Unless foam is flakey or torn badly you don't have to replace it normally. She also sprays it with Fabreze which removes all odors without leaving behind an odor of its own. If you have to cut new foam, the electric knife cuts it like butter. Use a marking pen to draw out the shape and size. Another tip: she says after you strip out the old cushions to use for a pattern, press the pieces first, it will be much easier to get the shape and size exactly the same as the originals. She says her labor for this job would be around $600 to $700. The whole job as as she did it for us would run about $1,500. Date: October 23, 2000 Hi Paul, Other than that. Considering that we are having a Dodger built as I write this, hopefully it will be fully installed Wednesday so that I can drive up Thursday take pictures , take everything down (dodger & bimini) get the winter covers on etc etc.---anyway considering the $ involved Judy and I will probably tackle the cushions ourselves with some help from the lady accross the streets mother. We'll wait and see, the foam on ours looks quite decent. (all 5" with exception of the salon back cushions).. Date: September 26, 2001 We just had SailNet (formerly JSI) redo all the foam on our E32. We created the templates by tracing the cushion space and they fit great! We did the sewing and they supplied the foam. We had SailNet make the v-berth in 3 pieces (instead of a single "V") so that it's easier to manage. We also went with laminated foam for the v-berth (3" of 50lb with 2" of 35lb on top--boy do they feel comfortable! We also went with a shaped/sculpted seat back in the satee area with everything held in palce with Velcro. The foam cost about $800 and the fabric, on sale, cost about $250. SailNet says that you need 17 yeards for the E32 but we bought 22 and had a lttle left over--if you buy an end of roll, make sure there aren't any flaws! You can do it with cheaper foam--about $450-500 if you go with the low end stuff. Speak with Steve Meadows. He's very helpful and informative. Date: October 16, 2002 Paul Uhl, The new owners are Bill Wright, Ken Clark and Mark Ploch. Ken was with JSI through much of the growth of the mid 80's and early 90's. Bill ran the sail loft at JSI for 5 years and then was the manufacturing manager for the entire facility. Mark has owned the local UK, then Doyle sail loft, plus Island Nautical Canvas and a Doyle loft in New York. I have remained with the new company and we have maintained all of our pattern base, which includes many of the Endeavour lines. I know your forum is not for commercial purposes, but I thought that you may be interested to know what has transpired over the last several months. Steve Meadows Date: March 11, 2004 I found a foam retailer / upholsterer in Raleigh, NC who has the template for the v-berth and pilot berth cushions on the E32. He is replacing with 4-inch foam and re-upholstering these for me with some very nice, woven Olefin fabric for $1500, including materials and labor. If anyone would like information, please e-mail me.
From: David L. Shelton david.l.shelton@Boeing.com
From: Paul Uhl endvr32@endeavourowners.com
From: Lois Seeley gseeley@blueplanet.net
From: Mike Miller capnmike_s@yahoo.com
From: Scott Ziegler scott.ziegler@attws.com
From: Josh Wallach hbs@flash.net
From: Fred VerPlanck fastfredv@earthlink.net
From: KMcEnery@Scholastic.com
From: Bob and Sandy Warren rwarren@inna.net
From: Bruceadele@aol.com
From: Paul Uhl endvr32@endeavourowners.com
That's pretty much what Barb and I are thinking about except we'll use all new materials. Could you tell me more about the foam? Are there different kinds? Was there a type or density that you used? I like the bedding factory idea. Did you have any problems? Did you have to give tham any dimensions or anles, or did you just give them the old ones and that was it? How did you attach the new cushions on the boat?
From: A.C. Whitlow sailcat@erols.com
From: Paul Uhl endvr32@endeavourowners.com
We were also thinking of vinyl on the back. Why the change of heart?
From: Phil & Monica flipper1@erols.com
From: Jack Newell jnewell@pmc-mail.com
From: Paul Uhl endvr32@endeavourowners.com
FYI: They have some of the patterns for the E32, but after talking with them I have every confidence that they would do an excellent job for ours. Apparently they were contracted by Endeavour to make the cushions for many of the original Endeavours in the 80's. They also currently make cushions for many production boats on the market today.
From: Carl Hibbard Chgypsy@aol.com
From: Paul Uhl endvr32@endeavourowners.com
JSI is sending me a package--it hasn't arrived yet but it's supposed to include alternate ways of approaching the seat back cushions. Ours are 'pillow' like things attached to a board which hangs on an interior storage bin opening. I'm considering a full length backrest instead so that the filler cushion for the pull out setee doesn't need to be removed from the pipe berth.
1.8lb foam = mid range
2.3lb foam = high range
From: Lois Seeley gseeley@blueplanet.net
From: Chris Berry berrycook@primary.net
From: Jim Moran OLDBLUE2@aol.com
From: Paul Uhl endvr32@endeavourowners.com
From: Pete Doddato lapdog@olsusa.com
From: Carl Hibbard Chgypsy@aol.com
Had a long talk with Steve Meadows of JSI today. Their firm did not do the bulk of Endeavour cushions. He said that they picked up the Endeavour contract in 1985, replacing an older family style firm where there was ill health. They did do the 38's, 42's, some 33's and 35's.
JSI has done some cushions for E37 "A"'s which I was interested in, and came up with rough estimates (new foam and material) of $2k to $2250. This estimate was not to include the filler matteresses for the table. Using my foam it was about $1.6k ergo covers only again no filler mattresses. BTW there records indicate that the quarter berths on the "A's" only had one cushion per side, interesting because ours has two per.
From: Paul Uhl endvr32@endeavourowners.com
From: Steve Meadows steve@newjsi.com
I thought I would drop you a line to let you know that SailNet has sold several of the manufacturing divisions to a group of ex-employees. The new company is Island Nautical Inc. d.b.a. JSI. The intent of the company is to return to the grass roots of people oriented service.
JSI Cushion and Canvas Sales
3000 Gandy Blvd
St Petersburg, FL 33702
800-652-4914
www.newjsi.com
From: Mike Hurley mchurley@mindspring.com
