8/13/24

A DIY Guide to Reupholstering Your RV's Captains Chairs

Hey there, fellow road warriors! Let's talk about something that gets a TON of use in any motorhome: the captain's chairs. They’re our thrones for long hauls, our swiveling command centers at the campground, & often, the first thing to show some serious wear & tear. If your rig’s front seats are looking a little sad—peeling, cracked, or just plain outdated—you've probably wondered what your options are.
Replacing them can be SHOCKINGLY expensive, & generic seat covers often look… well, generic. They slip, they slide, & they never quite fit right. But what about reupholstering them yourself?
Now, I know what you might be thinking. Upholstery? Isn't that for seasoned pros with secret knowledge & magical tools? Honestly, it's a project that requires patience, for sure. It’s tedious, but it's absolutely NOT impossible, even for a beginner with some basic sewing skills. Think of it as a super-sized, 3D puzzle. If you can follow a process & are willing to learn as you go, you can totally breathe new life into your chairs & give your RV a massive interior upgrade for a fraction of the cost.
This guide is your deep dive into doing it yourself. We're going to cover everything from picking the right materials to the nitty-gritty of taking your chair apart & sewing it all back together. So grab a coffee, & let's get into it.

Is This Project Right for You? A Moment of Honesty

Before we start pulling out tools, let's have a real chat. This isn't a quick weekend project. Depending on your skill level & the complexity of your chairs, this could take a few days. The first chair will be your learning curve; the second one will go much faster.
You should tackle this if:
  • You have basic sewing skills (you can operate a machine & sew a reasonably straight line).
  • You're patient & methodical. Rushing is your enemy here.
  • You're on a budget & want a high-end look without the high-end price tag.
  • You enjoy the satisfaction of a DIY project done well.
You might want to think twice if:
  • You've never touched a sewing machine. This is a pretty ambitious first project.
  • You need your RV back on the road ASAP.
  • The idea of dozens of fabric pieces & hog rings makes you break out in a cold sweat.
If you're on the fence, you can always consider professional reupholstery. It's a significant investment, often running from $600 to over $1,500 per chair depending on the fabric & complexity, but it guarantees a professional result. For comparison, a brand new, quality replacement chair from a brand like Flexsteel can easily cost $1,400 or more, plus shipping. So, DIY offers some serious savings.

Gearing Up: Your Supply & Tool Checklist

Alright, decided to press on? Awesome! Let's get our gear together. Having everything on hand before you start makes the whole process SO much smoother.
Essential Tools:
  • Heavy-Duty Sewing Machine: Your standard home machine might struggle. An industrial or heavy-duty machine is ideal for handling thick upholstery fabric & multiple layers.
  • Seam Ripper: This will be your best friend. You'll be using it to deconstruct the old covers.
  • Hog Ring Pliers & Hog Rings: These are special U-shaped staples used to attach the fabric to the chair's frame. You'll need wire cutters to remove the old ones.
  • Staple Lifter & Staple Gun: For removing old staples & attaching the new fabric.
  • Good Fabric Scissors: Sharp, quality scissors are non-negotiable for clean cuts.
  • Screwdriver & Ratchet Set: For disassembling the chair from its base & removing armrests or trim pieces.
  • Markers (Sharpies work great): You'll need a silver or light-colored one for dark fabrics & a black one for light fabrics to transfer markings.
  • Straight Pins & Measuring Tape
Materials:
  • Upholstery Fabric: We'll dive deep into this in the next section. You'll likely need about 4-5 yards per chair.
  • Upholstery Thread: Get a heavy-duty thread that matches your fabric. Don’t skimp here; this is what holds it all together.
  • New Foam (Optional): If your cushions have lost their bounce, now is the perfect time to replace the foam.
  • Spray Adhesive: A 3M upholstery adhesive is great for tacking foam to the frame & fabric to the foam in certain spots.
  • Dacron/Batting (Optional): This thin polyester layer goes over the foam to give it a softer, more rounded look & helps the fabric slide on easier.

Choosing Your Fabric: Durability Meets Style

This is the fun part! The fabric you choose will completely transform the look of your cab. But in an RV, it's not just about looks. Your captain's chairs are exposed to a lot of sun, temperature changes, & wear.
Here’s a breakdown of the best options:
  • Marine Vinyl or Faux Leather: This is a top-tier choice for RVs. It's incredibly durable, water-resistant, & a breeze to clean—a huge plus if you travel with kids or pets. It gives that high-end, luxurious look. The downside is that it's not very breathable, which can get a little sticky on hot days.
  • Woven Performance Fabrics (like Sunbrella or Crypton): These are fantastic options. Sunbrella fabrics are solution-dyed, meaning the color goes all the way through the fiber, making them incredibly fade-resistant. Crypton is another performance brand known for being stain-repellent & durable. They come in a huge variety of colors & patterns, allowing for more customization.
  • Microfiber/Ultrasuede: This synthetic fabric is designed for heavy use. It's soft, comfortable, scratch-resistant, & can even repel water. It has a suede-like feel without the high maintenance of real suede.
  • Sheepskin: A bit of a wildcard, but hear me out! Sheepskin is a favorite among pilots for a reason. It's naturally moisture-wicking, antimicrobial, & promotes better circulation, making it incredibly comfortable for long drives. It might not be for every design aesthetic, but for pure comfort, it's hard to beat.
Pro-Tip: No matter what you choose, look for a fabric with a high "double rub" count. This is a measure of abrasion resistance. For high-traffic furniture like a captain's chair, you want something rated for heavy use.

Step 1: The Deconstruction Zone

Okay, tools & materials at the ready? It's time to start the operation. It's HIGHLY recommended to work on one chair at a time. That way, you always have a fully assembled chair to reference.
  1. Remove the Chair from the RV: This just makes life easier. Captain's chairs are usually bolted to a motorized base. A simple ½" wrench should do the trick to remove the four bolts holding the seat to the base. You can leave the heavy motorized base in the RV.
  2. Take a LOT of Photos: Before you remove a single screw or staple, take photos of your chair from every conceivable angle. Pay close attention to how the fabric is tucked into crevices, where seams are located, & how trim pieces are attached. These photos will be your bible during reassembly.
  3. Disassemble the Components: Start removing the easy stuff first. This usually means the plastic skirts around the base, any levers for reclining, & the armrests. Armrests can be tricky; sometimes they pop off, other times there are hidden screws or pins. Go slow & investigate before you pry too hard.
  4. Label Everything: As you remove pieces of the old cover, label them with your marker. "Left Arm, Top," "Seat Cushion, Front," "Backrest, Right Side." This is CRUCIAL. You think you'll remember, but after a day or two, all those pieces of fabric will look the same.
  5. Mark Your Seams: This is a pro-level tip that will save you a world of headaches. Before you take the seams apart, use your marker to make "match-up" marks across the seams at various points. A simple line or a little 'X' that crosses from one panel to the other will help you align the new pieces perfectly when you sew. The more marks, the better, especially on curves.
  6. Carefully Rip the Seams: Now, with your trusty seam ripper, begin carefully taking apart the old cover, seam by seam. The goal is to separate the pieces without tearing the fabric, because these pieces are your new pattern! You'll also encounter staples & hog rings holding the fabric to the frame. Use wire cutters for the hog rings & a staple lifter for the staples. It's a bit of a treasure hunt.
Once you have the old cover completely deconstructed, you should have a pile of flat (or mostly flat) fabric pieces. These are your templates. Don't throw them away!

Step 2: Foam & Prep Work

With the chair naked, now is the time to assess the foam. Is it compressed, crumbling, or stained? If so, replacing it will make a HUGE difference in comfort.
You can often order pre-cut foam kits directly from the chair manufacturer (like Flexsteel) for about $75 a chair. This is the easiest route. Alternatively, you can buy a block of high-density foam & use the old foam as a template to cut the new pieces. An electric carving knife works surprisingly well for cutting foam.
When you install the new foam, use a bit of spray adhesive to tack it to the chair frame to prevent it from shifting around. If you're adding Dacron, lay it over the foam before you put the new covers on.

Step 3: Cutting & Sewing Your New Covers

This is where the magic happens. It's time to turn that beautiful bolt of fabric into a new chair cover.
  1. Layout & Trace: Lay your new fabric out on a large, flat surface, backside up. Arrange your old pattern pieces on top of it, making sure to align any patterns or fabric grain consistently. Carefully trace each piece with your fabric marker. Double-check everything before you make a single cut. Remember the old carpenter's rule: measure twice, cut once.
  2. Cut Your New Pieces: Using your sharp fabric scissors, carefully cut out all of your traced pieces. As you cut them, transfer the match-up marks & labels from the old pieces to the new ones.
  3. The Sewing Begins: Now, working piece by piece & referencing your photos & labels, you'll start sewing the new cover together. This is essentially the reverse of how you took it apart. Pin two corresponding pieces together (right sides of the fabric facing each other), aligning your match-up marks.
  4. Sewing Heavy Fabrics: Use your heavy-duty thread & a strong needle (a size 130/21 or 140/22 is a good starting point). Go slow, especially around curves. You don't need a fancy machine, just one that can handle the thickness. A "walking foot" attachment can be a lifesaver, as it helps feed the top & bottom layers of fabric through the machine at the same rate.
  5. Top Stitching & French Seams: Many captain's chairs have decorative topstitching or French seams. A top stitch is a line of stitching on the "right" side of the fabric for decoration & strength. A French seam is where you see two lines of stitching. These are a bit more advanced but totally doable. A twin needle can help create perfect parallel stitches. There are great YouTube tutorials that break down these techniques for beginners.
  6. Leave an Opening: As you sew, remember to leave one or more seams open, usually on the bottom or back of a piece. This is how you'll get the cover back onto the chair. Some people even sew a zipper into this opening to make the covers removable for future cleaning.

Step 4: The Final Assembly

You're in the home stretch! Your new cover is sewn, & your chair frame is prepped. It's time to put it all back together.
  1. Dress the Chair: Carefully work your new cover over the foam & frame. This can be a bit of a wrestling match. Be patient & don't force it. Gently pull & smooth the fabric into place.
  2. Staple & Hog Ring: Once the cover is on, flip the chair over. Start pulling the fabric taut & securing it to the frame underneath using your staple gun & hog ring pliers, just like the original. This is what gives the upholstery its tight, professional look.
  3. Hand Sewing: The openings you left will now need to be sewn shut by hand using a curved upholstery needle & strong thread. A blind stitch is a great technique here, as it will be nearly invisible.
  4. Reattach Components: Now, simply reattach the armrests, levers, & plastic trim pieces in the reverse order you took them off.
  5. Reinstall in the RV: The final, glorious step! Bolt your beautifully reupholstered chair back onto its base in the RV. Sit down, swivel around, & admire your handiwork. You did it!

A Quick Note on Storage & Workspace

A project like this takes up a surprising amount of space. You'll have chair parts, foam, tools, & large cuts of fabric spread out. If your driveway or garage is already packed, it can make the whole process feel chaotic. If you need a temporary, dedicated project space, you might want to look into renting a neighbor's garage for a short period. It sounds a little out there, but platforms like Prked are making this pretty easy. You can find affordable, convenient spaces right in your neighborhood, which could be a game-changer for keeping your project organized & out of the elements. It's also a great way for homeowners to make a little extra cash from their empty garage space—a win-win!
I hope this guide has demystified the process of reupholstering your RV captain's chairs. It's a challenging but incredibly rewarding project that can completely revitalize the interior of your home on wheels. Take your time, trust the process, & don't be afraid to step back & consult your photos.
Let me know what you think in the comments! Have you ever tackled a project like this? Any tips to share?
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