---
title: "Extra Long Bench Cushion in One Piece: 138 in Has Been Made"
url: "https://cushionguide.com/answers/longest-single-piece-cushion/"
section: "The Cutting Table"
author: "Callum Reid, The Weather Man of Casco Bay"
author_url: "https://cushionguide.com/masters/callum/"
published: "2026-09-18"
updated: "2026-09-18"
keywords: "extra long bench cushion one piece, long window seat cushion, one piece vs two piece cushion, custom bench cushion length, seamless bench cushion"
---

# What's the longest cushion you can make in one piece?

*Long runs are where tailors start talking you into two pieces. Here's what has actually been made seamless, and why the workshop still suggests halves.*

Also asked as: Longest possible cushion as one piece?; Can the 104 be one piece instead of two 52s?

> **The quick answer:** Single cushions up to 40 x 138 in (102 x 350 cm) have been made in one piece on request, so a seamless run is usually possible. The workshop still recommends about 79-91 in (200-230 cm) per piece and often suggests two equal halves, which are easier to make, ship and handle. Write 'one piece' in the order if you don't want a center seam.

![Deep teal velvet window seat cushion with a ginger cat asleep beside an open book and oatmeal throw](https://cushionguide.com/media/window-seat-cushions/deep-teal-velvet-window-seat-cushion-sleeping-cat-928.webp "The warmest seat in the house: deep teal velvet in the afternoon sun, already claimed by the cat.")

## Key facts

- Single cushions of 82 in, 104.5 in, 111.5 in, 118 in (3 m) and 138 in have been made.
- An 84 x 59.5 in (214 x 151 cm) window seat was made in one piece, without tufting.
- The recommended maximum is about 79-91 in (200-230 cm) per cushion.
- Two equal pieces are often suggested for very long runs, such as 2 x 58 in for 116 in.
- Very long single pieces may vary by 1-2 in, though each is measured before shipping.
- Write 'one piece' in the order to avoid a center seam.
- A 170 in run had to be made in at least 2-3 pieces.

## Can a 138-inch window seat be one piece?

A buyer in the US had a 138 in window seat and didn't want the usual two halves. One continuous piece, please.

The workshop said yes. The cushion was cut at 40 x 138 in, 3 in thick, in linen with velvet piping, and made as a single piece. That size was added to the listing so the buyer could check out.

So the answer to 'can the 104 be one piece instead of two 52s' is also yes. A 104.5 x 18 in bench cushion went out seamless for another buyer who simply asked.

## Then why does the workshop keep suggesting two?

Because a long cushion handles like a wet sail. It's awkward to sew, awkward to box and awkward to carry through a doorway. Two equal pieces are easier to make, ship and handle, and they fit the bench better over the years.

The workshop's working limit is about 79-91 in (200-230 cm) per piece. Past that it will often propose halves: 116 in as 2 x 58 in, or two 59 in (1.5 m) pieces. You can still say no. The trade-offs are laid out in [one long cushion or two](https://cushionguide.com/guides/long-bench-cushion-one-piece-or-two/), and the [bench cushion](https://cushionguide.com/cushions/bench-cushions/) hub has the measuring basics.

## And past about 136 inches?

Tolerance gets looser, friend. At around 136 in, a single piece may come out 1-2 in off, even though it is measured before it ships. Read [custom cushion size tolerance](https://cushionguide.com/guides/custom-cushion-size-tolerance/) before you commit to one long run.

There is a ceiling, too. A 170 in run had to be made in at least 2-3 pieces, and a bay seat over 14 ft went in two. How long is yours, wall to wall?

## Long runs that have been made, and how

| Run | Made as |
|---|---|
| 82 in | One piece |
| 104.5 x 18 in | One piece, on request |
| 111.5 in | One piece |
| 118 in (3 m) | One piece |
| 40 x 138 x 3 in | One piece, linen with velvet piping |
| 84 x 59.5 in (214 x 151 cm) window seat | One piece, no tufting |
| 116 in | Suggested as 2 x 58 in |
| 170 in | At least 2-3 pieces |

> **Tailor's margin:** Write 'one piece' in the order note of any cushion longer than about 91 in (230 cm), or the workshop may suggest two equal halves.

> A 40 x 138 in window seat cushion has been made in one continuous piece; past about 91 in, the workshop still suggests two equal halves.
>
> — Callum

## Buyer questions

**A common question:** What's the longest bench cushion you can make as a single piece?

**The workshop's answer:** A very long cushion like 102 x 18 in can be split into two equal pieces of 51 x 18 in, but the workshop can also make it as one continuous piece if you prefer.

**A common question:** Can a 136-inch cushion be made in one piece?

**The workshop's answer:** The workshop recommends two pieces. One piece is possible, but at that length allow a possible 1-2 in difference, even though every cushion is measured before shipping.

**A common question:** Should a very long seat be split, and into how many pieces?

**The workshop's answer:** The workshop recommends pieces of about 79-91 in (200-230 cm) at most, because they fit better, last longer and are easier to handle. A bay seat over 14 ft was made in two pieces and a 16.4 ft (5 m) indoor sofa seat in three. A single piece can still be made on request.

**A common question:** Will you really make a very long cushion in one piece?

**The workshop's answer:** Yes. Cushions of 111.5 in, 104 in, 82 in and 118 in (3 m) have been made as single pieces. For very long runs the workshop sometimes suggests two pieces because they are easier to handle and ship, but one piece stays an option.

## Questions buyers ask next

### Can a tufted cushion be made extra long in one piece?

Very long tufted seats are usually split into equal pieces, for example a 122 in (310 cm) seat as two 61 in (155 cm) cushions. The one-piece 84 x 59.5 in window seat on record was made without tufting.

### How close to my ordered length will a long cushion be?

Sizes are made as written, not rounded, but handmade cushions can vary by about 0.5-1 in, and very long single pieces around 136 in by 1-2 in. Each one is measured before it ships.

### Where does the joint fall on a two-piece bench cushion?

In the middle. The workshop splits long runs into two equal pieces, such as 116 in as two 58 in cushions or 102 in as two 51 in cushions, so the pieces meet at the center of the bench.

## Related at the atelier

- [One long cushion or two? Splitting a long bench or window seat](https://cushionguide.com/guides/long-bench-cushion-one-piece-or-two/): A long bench cushion is usually best split into equal pieces once the run passes about 79 to 90 in (200 to 230 cm).
- [My cushion is bigger than the largest size on the listing. Can I still order it?](https://cushionguide.com/answers/cushion-bigger-than-largest-size-option/): Yes: choose the largest size option and write your exact measurements, or upload a drawing, and the cushion is made to that size.
- [My size falls between two options. Which one do I choose?](https://cushionguide.com/answers/size-between-two-options-which-to-choose/): Choose the next larger size option, the one just above your measurements, and write your exact size in the personalization or note-to-seller box.
- [Can you remake my sofa's seat cushions, or replace them with one long cushion?](https://cushionguide.com/answers/replacement-sofa-cushions-custom-size/): Replacement sofa seat and back cushions can be made to your exact measurements, with the thickness matched to the originals, and three seat cushions can become one long cushion with no seams across…
- [Garden Bench Cushion in Harlequin With One Long Navy Back](https://cushionguide.com/readings/harlequin-seat-navy-back-cushion-teak-garden-bench/): To mix patterns on an outdoor bench, let one piece carry the pattern and take the plain piece from its darkest color: here a navy, red and green harlequin seat under one long navy back cushion.
- [Custom Bench Cushion for a Dining Bench: Keep It Near 2 Inches](https://cushionguide.com/readings/taupe-ticking-stripe-pad-scandi-oak-dining-bench/): A custom bench cushion for a backless dining bench works best at about 2 in (5 cm) thick, so people on the bench sit level with the chairs opposite and their knees still clear the table.
- [One printable cushion measuring worksheet for any shape you order](https://cushionguide.com/guides/printable-cushion-measuring-worksheet/)

*Fair winds — Callum*

---

Written by Callum Reid (https://cushionguide.com/masters/callum/) for CushionGuide (https://cushionguide.com/about/). The site explains made-to-measure cushions and the partner workshop makes them; measurements are in inches first. This Markdown mirrors the page at https://cushionguide.com/answers/longest-single-piece-cushion/