Recovering an aircraft seat is well within reach for a capable shop or owner — the sewing is much like marine or auto work. What’s different is the compliance layer. Get the material and paperwork right and the rest is craftsmanship. Here’s the process, with the aviation-specific parts flagged.
Before you cut: get the right material
Cabin upholstery generally has to meet FAR 25.853 flammability requirements. Start with vinyl that’s listed by its manufacturer as meeting FAR 25.853A, and make sure you’ll get the burn certificate with your order — your mechanic needs it for the file. (More on that in our aviation vinyl guide.)
The process
- Remove the old cover carefully — pull staples without tearing it. The old cover is your best pattern.
- Inspect the foam. Aircraft seat foam has its own fire-rating requirements; if it’s shot, replace it with aircraft-rated (FR) foam — a different product from standard upholstery foam.
- Cut the new vinyl using the old cover as a template; add a little for wrap and staple.
- Sew it up with color-matched thread for a clean, factory look.
- Reinstall — pull tight, staple evenly, and let your A&P/IA make the airworthiness call and sign-off.
Your materials checklist
- FAR 25.853A-listed cabin vinyl — we use Spirit Millennium
- Burn certificate (ships with every Carolyn Fabrics aviation order)
- Color-matched thread
- Aircraft-rated FR foam — sourced separately for your application
Not sure how much vinyl your seats need? Our project builder sizes it for you and matches the thread.
Carolyn Fabrics supplies upholstery materials and the manufacturer’s flammability (burn) certification documentation. We do not determine airworthiness. Final compliance, installation, and airworthiness determinations for your aircraft are the responsibility of the installer/owner and certifying mechanic under applicable FAA regulations.