- 1). Measure the width of the box cushion along the back side where the zipper will be installed. Add 12 inches to the width. Measure the height of the side of the cushion. Cut two pieces of fabric to these measurements. Cut the zipper to the full length measurement, add the lever and zip the zipper closed so the zipper lever is 2 inches from one end.
- 2). Place the fabric face sides together. Sew a double-stitch seam 1 inch long and 3/4 inch from the edge. Repeat for the second side.
- 3). Iron the seams flat. Continue folding the fabric in the direction of the flat seams 3/4 inch and iron both sides. Place the fabric face down on the table. The inside folds should touch evenly along the length.
- 4). Position the zipper lever side down over the seam and where the folds touch. Pin the zipper to the fabric making sure the folds continue to touch as you pin. Sew the zipper to the fabric using a zipper foot on the sewing machine. Cut two 1-by-1-inch pieces of fabric.
- 5). Place the fabric over the zipper. Sew across the width of the fabric 1/2 inch from the edge. Be careful not to break your needle as you sew across the zipper. Sew across the fabric piece as it covers the zipper. Repeat for both ends.
- 6). Measure the thickness of the cushion and add 1 inch for seam allowances. Center the zipper in your measurement and trim the excess fabric from the outside edge of the zipper panel so the panel will be the same thickness as the rest of the side panels.
- 7). Overlap the adjacent end of the side panel of the cushion cover 2 inches from the end of the zipper panel. Sew a seam perpendicular to the zipper until you reach the zipper, pivot the fabric and sew along the edge of the zipper toward the end of the panel. Pivot at the seam 1/2 inch from the end and carefully sew across the zipper again. Pivot and sew along the side of the zipper away from the end 1 1/2 inches. Pivot, matching the 2 inches from the edge seam and continue to the edge of the panels. This will create a pocket that hides the zipper lever.
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