Our much loved leather sleeper sofa had become so saggy our backs got sore and we could barely get out of it. We added a sheet of plywood under the cushions to firm it up but then it was like sitting on a brick. We eventually realized the problem was the cushions had worn out. The solution was replacing the foam inside. It’s possible to buy foam already cut to size and even wrapped with a batting which protects the foam and fills out the cushion nicely. However ordering those requires exacting measurements and can cost over $100 per cushion. I chose to buy one large piece of foam and a separate roll of batting from The Foam Factory for $80 total to my door. This made 3 cushions with some foam left over. One complexity is knowing which foam to pick, there are many options with different firmness, longevity, and materials. I guessed we wanted a medium firmness (36 lbs ILD) and did not need high quality as this would become secondary seating.
I cut the foam with a bread knife and followed their directions on stapling the batting. It took simple tools and a couple hours but now the couch is like new. One trick I learned is rolling the cover off the old cushion allowed you to easily unroll the cover onto the new cushion without having to fight to stuff it in smoothly.
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