http://winterssewing.com/node/22
http://www.upholster.com/howto/
http://www.carrscorner.com/whyupholster.php
http://www.carrscorner.com/yabbse/
http://www.mormonchic.com/crafty/wingback.asp
http://www.how-to-videos.info/FurnitureUpholstery.html
http://georgemfabric.com/yardage.htm
http://www.rochfordsupply.com/product_listing.asp?catid=422&subcatid=514&prodid=3493

Hi Sky, these are some of the websites I've checked out, some better than others but all interesting and informative.
I'm not sure about button thread. I tried regular thread one night when I ran out of upholstery thread and it just kept breaking. I was hand sewing and really trying to pull the seam tight, finally just packed it up for the night and went out for upholstery thread the next day.
I've always just sewn plain seams. I am in no way an expert. Have just recovered a few chairs but the best advice I can give is to take a bunch of digital pictures as you remove the cover that is now on the chairs and take notes. Use those covers as pattern guides for new material BUT be sure to cut larger -- you need the extra material to be able to pull everything tight.
I hope some of this makes sense. Hopefully others will jump in with more advice. I also found books at the library that were really helpful. Sorry, can't remember names of the books. I just brought home an armload and read through them.
With your sewing experience and being a perfectionist, I have no doubt you will do a beautiful job. Be sure to post before and after pics and good luck.
Mari

mry193, thanks for your response. I didn't even know there was upholstery thread - now I know to look for it. I did find on the ultrasuede website that I should use polyester thread. I also appreciate your links, I didn't find any of these when I googled. And yes, I'll post pictures of before and after.

Again, thanks,

Sky

Thread comes in different weights and fibres (you already know that). I'd be looking at using a polyester thread, too (cotton will rot with time and esp. if subjected to changes in humidity and sunlight, ditto the latter with respect to nylons), and use your judgement with respect to the weight of it, you know the hand of the ultrasuede you purchased. Off the top of my head, I'd think 69 weight or maybe one step "lighter" would be pretty good.

Use a longer stitch and really make the time to play around with the tension adjustment on your machine; I don't use them much, but you may want to consider using a leather needle if you can get one for your machine. I would definitely fool around with both types of needles and see which one gives you the best result. You can use a plain seam or if you want you can topstitch the allowance to one or both sides of the seam for an added detail. Depends on what sort of "look" you want. Personally, I tend to think that topstitching lends a more casual/"masculine" feel to a project and can look great when done well or REALLY amateur if done sloppily.

I don't know what sort of machine you use, but ultrasuede (and leather) can be sort of stretchy, esp. when you begin working with multiple layers (applying the boxing to a corded piece, for instance). My machinery is industrial grade and the machine I use for upholstery work is a needle feed and has a walking foot; I have a variety of outer cording feet to accomodate different insert diameters. That combination makes feeding multiple layers evenly A LOT easier than it would be on a drop feed machine (this is what home machines use). I suspect, if you're using a home machine, you will find applying the cording and the boxing the toughest part of the operation. I'm basing that on the supposition that you will be using an adjustable zipper foot and may lose up to 50% of the feed dogs' ability to pull multiple layers under the needle bar. Go slowly and be ready to "help" your machine when you hit areas of greater bulk.

Sounds like a fun project.

Chelone, I was hoping you'd answer. Yes it's a home machine and thankfully the style doesn't call for cording, just simple seams which is why I figured I'd be okay. I may top stitch but I'll see how the seams lay first - I read that ultrasuede doesn't always want to lay flat open in seams. I will go slow and I hope that my years of sewing kids clothes in heavy velour with cording, zippers etc. will provide me with the experience of helping the fabric feed evenly when the machine can't handle it. I wish I had an industrial machine, but then the reality is I wouldn't know how to operate it optimally. Actually I wish I had your knowledge and experience LOL. Again thanks for your help.

Sky

Sky., make the time to do an experiment with topstitching. I typically lap the allowance to one side, you might try trimming away the bottom allowance so you only have to stitch through 2 layers instead of 3. This might make things easier.

But DO watch out for stretch... I have seen many "come to grief" because of it.

As for an industrial machine... once you've worked on one you will never look at a home machine again. Really. And as for using it effectively? in a day you would have it "wired". Typically, people are afraid of them because they sound "loud" and they're a lot "faster" than a home machine. But once you understand that a clutch motor is SAFER than a home machine your horizons are greatly increased! Trust me on this point, I have taught many, many people to sew/stitch in production settings and as soon as they understand how to use the knee lifter and the brake their "fear" evaporates and their confidence soars.