Why worn denim makes such good cushions

Denim is one of the most underrated fabrics in a maker's stash. It is dense, hard-wearing and takes a surprising amount of punishment, which makes it ideal for anything that gets leaned on daily — and a cushion is exactly that. A pair of jeans that has gone thin at the knees but still has sound fabric across the back and thighs will yield enough squares for a decent-sized cushion, and the faded patches are the very thing that gives the finished piece its character.

The honest pleasure of this project is that it costs almost nothing. Two pairs of jeans in different washes — one dark indigo, one pale and worn — plus an hour or two at the machine and you have a sturdy, one-of-a-kind cushion. It is also a friendly second or third project for anyone who can sew a straight line and fancies trying patchwork without wrestling with fiddly, slippery fabrics.

What you will need

• Two or three pairs of old jeans, ideally in contrasting shades — dark indigo, mid-blue, faded grey and black all sit well together
• A 40 cm cushion pad, in feather, hollowfibre or wool as you prefer
• A rotary cutter, cutting mat and quilter's ruler, or sharp dressmaking shears
• A denim or heavy-duty machine needle, size 90/14 or 100/16
• Good-quality polyester thread in a mid-denim colour, or a contrast thread if you want the stitching to show
• Pins or clips, plus a fabric marker or tailor's chalk
• An iron and ironing board, which matter more here than you might expect

Wash and dry the jeans before you start. Denim shrinks, and second-hand jeans carry years of dust, so a warm wash and a full dry before cutting will save you from a cushion that goes baggy the first time you clean it.

Cutting the jeans down

Lay each pair flat and cut away the waistband, the zip and the side seams. The back of the legs is usually the least worn area and gives the biggest uninterrupted pieces; the thighs come a close second. Avoid cutting through thick, bulky seams wherever you can — they will make your machine cough and your patchwork lumpy. If a stubborn seam runs through a piece you want to use, trim the seam allowance right down to a couple of millimetres first.

For a 40 cm cushion, cut twelve-centimetre squares. With a one-centimetre seam allowance all round, each square finishes at ten centimetres, and a four-by-four grid gives a front measuring roughly 40 cm square. Cut thirty squares for the front so you have room to shuffle the layout. Try to keep the grain running the same way on every square — patchwork always looks calmer for it.

Arranging the patchwork

This is where the cushion starts to look like something you would actually want on a sofa. Spread the squares on the floor or a large table and move them about until the shades are pleasingly mixed. A few things worth trying:

• Distribute the darkest squares evenly rather than letting them clump in one corner.
• Mix the wear — put a soft, whiskered square next to a crisp dark one.
• Try a diagonal arrangement of lights and darks if you want something more deliberate than a random scatter.
• Include one feature square made from a back pocket, or a patch trimmed from a hem, for a bit of narrative.

Photograph the final layout on your phone before you move anything. It is remarkable how quickly an arrangement escapes you once the squares are in a pile.

Sewing the cushion front

Join the squares into rows first, then join the rows together. Place two squares right sides together, pin, and sew with a one-centimetre seam allowance and a slightly longer stitch than usual — around three to three and a half millimetres. Denim is heavy and a longer stitch helps the machine cope. Backstitch at both ends of every seam.

Press each seam open as you go, working from the wrong side, and use a little steam. Trim the seam allowances to about seven millimetres after pressing where the denim feels bulky; this makes the whole front lie flatter. When the four rows are joined, press the long seams open too, then give the panel a final press from the front through a cotton cloth. Even up the edges with your ruler and cutter.

Making the back and finishing off

An envelope back is far easier than a zip with fabric this thick, and it looks neat. Cut two rectangles from the remaining denim, each roughly 42 cm wide by 30 cm deep. Hem one long edge on each — fold over one centimetre, press, fold again, and topstitch. Overlap the two panels so the total depth is about 42 cm, pin them to the front with right sides together, and sew all the way round with a one-centimetre seam allowance. Snip diagonally across the corners, turn the cover right side out, and press.

Slip in the cushion pad and your jeans have a second life. Wash the cover inside out on a cool cycle and line dry it — never tumble denim if you want it to keep its shape.