How best to repair a rip in the cushion support of an Ikea POÄNG chair?

Post date: 2022-06-23 17:45:45
Views: 59
I have an Ikea POÄNG chair that has a rip in the square piece of polypropylene fabric that supports the bottom cushion. I would like to fix it both cheaply and securely.

(You can see images of the part and of the rip here.)

As it supports the "seat" of the chair, I want any repair to be secure as it supports the bulk of the weight of the person sitting.

The weave of the fabric mesh looks similar to burlap/loose canvas but is made from 100% polypropylene. Before I knew it was polypropylene, I thought I might be able to use a couple of those old iron-on-denim patches for jeans, but now I think that any sort of such heat would just melt the polypropylene.

I have talked to Ikea, but this polypropylene mesh piece is not one of the replaceable parts they offer.

If I replace the fabric with canvas or something, it would require removing the staples that afix the old mesh to the sides, and in putting in new staples, and I imagine they wouldn't hold nearly as strongly in the old holes, and that they no doubt use industrial-strength staplers in the Ikea factory anyway.

I've looked on Amazon for repair ideas, and so far it looks like maybe this TEAR-AID might work, or maybe if I cover both sides with several criss-crossing strips of cloth-backed gaffer tape (which I know is darned strong, but also kind of ugly—although it would be unseen under the cushion). Honestly, the gaffer tape idea sounds like the easiest, but would look ugly if seen without the cushion.

The only other idea I had was if I took two square pieces of canvas, each large enough to cover the non-wood-backed part of the mesh, slather one side of each piece with some sort of industrial adhesive, and then sandwich the polypropylene mesh, tear and all, between them—hoping that the adhesive would both hold the canvas to each side, as well as permeating through the mesh and creating a bond like a grilled cheese sandwich... (this way sounds more expensive and iffy)

Or I could get rid of the mesh completely, drill a bunch of evenly-spaced holes in the plywood edge pieces, and weave a grid of rope similar to this (but with the holes going through the (ply)wood vertically, not horizontally as with the stool in this picture). Although that would be most-likely affecting the strength of the chair since I would be putting a couple of dozen holes in the plywood structure...

Has anyong done a similar repair before?
Any ideas?
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