Most upholsterers will be able to do this for you. You can also order foam, cut to your specs, from some suppliers, but then you will have to wrap with Dacron, and muslin, if desired. Here is a link that might be useful: sunshine foam

You will have to go through a dealer, B-Y does not sell direct, even parts. I'm a B-Y dealer and will be glad to handle this for you, simply box up your casing and UPS to me. Email me at dcollie@keepingroom.com for specifics. The old casing is required for a hide match and tailoring sizing, and even then it will not be exact. Cost estimate? Probably $ 100 to $ 180. -Duane C

I recently bought a couch rom Ralph Lauren and it came with ultra blend couch cushions. The cushions started to flatten. I did;t know a whole lot about couch cushions. they are willing to replace the cushions for more firm cushions, however they do not have the two most firm cushions to sit on in the store for me to try. These are the two cushions I have to choose from. the representative at Ralph Lauren is saying that the Luxury foam fusion is the most firm and the Springdown is 2nd most firm. Please anyone give me advice on what you would pick. I am attaching the discription of both cushions. Please help me decided what to get. I would like something very firm, this couch needs to last us a while, and it is our main couch, so lots of people will be sitting on it, I am looking for most firm couch. However, wouldn't an all foam couch be not so firm and a spiring couch be more firm. Anyway please see attached photos for description.

There are some good foam spray adhesives out there. I used some to glue 2 cut scraps into one chair seat. But sometimes couch cushions are rounded on the edges, which wouldn't work good for an overall smooth look imo. Do the covers come off for you to inspect the foam inside? That would be the first step to check out. If they are equal sizes with smooth cuts and 90 corners, then I'd probably try gluing them together first and see how it looks and works. Worst case, it sucks and you buy new foam, which you may do anyway. I have a local foam store where I purchase my supplies, so maybe google that in your area. They have all kinds of foam options (thickness, firmness, etc) with higher quality at competitive prices to hobby stores. As far as reusing the fabric, I don't think that would look good to have a seam down the middle, plus you wouldn't have any allowances left. So buy new of that. I have found many great tutorials and products on this website, including this adhesive. adhesive: https://www.sailrite.com/NG633-Foam-Lock-Spray-Adhesive-12oz