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[Funkmonkey]

Just starting out with auto/rv upholstery.

I’m recovering a sofa that has cushions with zippers. I’ve been using 1/4” sew foam on the new panels. It’s coming out well except for the sections that affix to the zippers. They really bulky. Any advice or techniques for handling these situations?

[Adam12]

Couple options, you can sew the zippers on before and glue the foam separately if it's 2 separate pieces. You can also sew the zipper down flat and then just split the vinyl down the center of the zipper. Leaves a raw edge but zippers are hidden from sight anyway. Could also score/peel away foam from where you intend to sew them.

[Rhonda]

Question how big is your hem? It may need to be trimmed ! you could do as @Adam12 said trim back the foam .