Replacement Foam for Cushions
When weaving with Shaker Chair Tape, the space between the upper and lower layers of tape is stuffed with a firm foam rubber cushion (the Shakers used horsehair or other materials), not only for comfort, but also to maintain contact between the two layers so that the lower layer helps support the weight which would otherwise be carried only by the upper layer of tape. This prevents sagging and reduces wear.
Mid-way through the weaving process, the weaver slides the foam cushion into the space between the upper and lower layers of warp. Trim the cushion to size with scissors, if necessary. To prevent the corners from showing once the seat is completed, trim off a small triangle (1" or so) from each corner.
For a firm and comfortable seat cushion, we use a urethane foam with a density of 1.8 pcf and a compression of 40-50 IFD. Made in USA.
WARNING: All urethane foams will burn. Do not expose to any flame source or high temperature ignition source, such as cigarettes, space heaters, or naked light bulbs.