Brown Jordan Replacement Cushions — Custom Cut, Any Collection
Cast aluminum from the 1945 founder of glamorous outdoor living — replacement cushions cut to your measurements, factory-direct, in Sunbrella-class solution-dyed acrylic. The reference sizes on this page come from independent specialists; your tape measure is the number we cut to.
Start with your shape
Not sure? Pick the closest — every measurement is confirmed before we cut.
Don't see your shape? We make any shape.
Straight edges? A top photo + the edge numbers is all we need. Curved? Trace it on paper next to a tape measure and email us a photo.
Enter your measurements
Measure the old cushion flat, edge to edge — never the frame.
Choose your fabric
Five families, 119 cuts, one flat rate — pick by look and feel. Click a family to see its swatches below, or its ⓘ for what the fabric is and where it works best.
All covers cut to your exact dimensions — no stock sizes, zippered covers that remove for washing.
Review & order
Calculated live from your measurements — every line, no surprises.
Free shipping over $158 · $29 flat below
Estimates only — we re-verify every dimension before cutting and will contact you if anything looks off. Prefer email? Email me this quote
Odd shape or tricky frame? Upload a photo of your furniture or old cushion — one overall shot, plus a top and side view of the old cushion if you can.
JPG, PNG or WebP · up to 10 MB each · max 3
The workshop that cuts it is the one that ships it
Every fabric on the list, open in the configurator
Measured cuts, not stock-chart guesses
Miss on our side and the remake is free
What Brown Jordan Actually Is — Outdoor Furniture Since 1945
Brown Jordan is the oldest name in American luxury patio furniture: founded in Southern California in 1945 by Robert Brown, who set out to build furniture that could live outdoors all year and still look like sculpture — hand-forged lightweight aluminum, five-step pretreatment, powder coats applied by hand. Pieces from the White House Rose Garden to the Hotel Ritz in Paris carry the badge; the frames routinely outlive several sets of cushions.
The official route for replacement cushions runs through your local retailer — the factory’s own FAQ says so, and publishes no size chart (a Venetian lounge-chair replacement lists at $412 with a third-party specialist; the reference table sits below). What a custom mill adds is everything the official route doesn’t publish: single pieces without a dealer quote, any density from 35D to 65D, 119 fabrics at one flat rate, and your measurements deciding every cut.
Brown Jordan pieces on a covered lanai or three-season room? Switch the customizer to indoor fabrics → — breathable weaves for furniture that lives under cover.
Published Brown Jordan Cushion Sizes — Specialist Reference
As published by third-party cushion specialists patiopvc.com and replacementcushionsonline.com (checked October 2026; SKUs listed so you can cross-check yourself). Brown Jordan itself publishes no replacement-size chart — official cushions are purchased through its retailers. Treat every figure as a reference to measure against: your tape measure is the number we cut to.
Pricing — estimated starting at
*One Florentine club seat block (23 × 24 × 4 in., 3.8 sq ft): $45 make-base + 3.8 sq ft × rate ($29.47 per sq ft, 4″ 50D foam + any of the 119 fabrics — fabric prices flat) ≈ $158. In 65D the same block runs ≈ $165; the configurator figures your exact numbers live.
The specialist routes list the comparable Florentine club set at $225 and a Venetian lounge-chair replacement at $412, both on 3–4 week lead times. Blocks built from your measurements start at the estimate above and ship in days.
Where Your Set Lives — Two Different Generations
Both generations share the same math: a frame built for generations wrapped in foam built for seasons. Identify which yours is before ordering — the fill and fabric specs are different jobs, and the comparison table maps the two.
Measure Your Piece — Three Numbers, One Photo
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- Width first, frame over foam — inside edge to inside edge of the aluminum frame where the cushion sits. Measure the frame whenever the frame is bare; measure the old cushion only when it is not. n
- Depth front to back — the published Florentine arm-chair pad runs 22″ wide × 18″ deep; if your tape says otherwise, your tape wins and we cut to it. n
- Thickness at the seam — measure the old cushion’s side, not its domed top. The order forms take increments to ⅙″; record to the nearest quarter inch. n
- One photo, straight-on — with the three numbers it settles every question the order desk would otherwise call you about. n
Fabric Options — 119 Fabrics, One Flat Rate, Free Swatches
Brown Jordan’s own care guide cleans its cushions with mild soap and water and rules out machine washing, tumble drying and dry cleaning — these are cushions built around performance fabrics. Our replacements follow the same logic: the solution-dyed acrylic (Sunbrella-class) line is the outdoor standard — fade-stable and quiet under rain — and every fabric on the list prices the same, so the choice is touch and duty, not markup. Free swatch cards on request: see and feel the exact cloth before anything is cut.
Brown Jordan Collections We Cut For
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- Current cushion collections — Calcutta, Huntley, Luca, Moto, Palmetto, Sol Y Luna, Solenne, Still, Trentino and Venetian, as carried on the factory’s own navigation. n
- Icon and heritage lines — Walter Lamb and the classic cast-aluminum era pieces; send a photo and we cut to the old pad. n
- Retired classics — Tamiami, Florentine and the mid-century lines third-party specialists still chart. n
- Lounge chairs and chaises — one-piece and multi-block loungers, curve-front seats included. n
- Dining and bistro pieces — slim dining pads from 2″ up, cut to your numbers. n
- Ottomans, benches and daybeds — single blocks any size; long runs are routine cuts here. n
A few from the 119-fabric lineup — review the full set, zoomed, in the configurator first.
What the official Brown Jordan route covers (and what a mill adds)
The official channel is design-first: brownjordan.com catalogs the furniture, its care and warranty pages, and a technician locator for refurbishment — and its FAQ routes replacement cushions to your local retailer, with no published sizes. Third-party specialists fill the gap with charts like the Florentine table above, from $46 arm-chair pads to a $412 Venetian lounge set on 3–4 week lead times. What none of them do is your number: a density they don’t list, a fabric outside their card, the single lost block without a dealer visit — those orders come to a workshop that cuts to measurements.
One distinction worth knowing before either route: some specialists also sell replacement covers. Covers re-dress sound foam; replacement cushions renew the foam itself. Seats that have gone soft need cushions, not covers — the deeper comparison is in our cushion covers vs full replacement guide.
Frequently asked questions
Three numbers and a photo. Width inside the aluminum frame, depth front to back, thickness at the seam edge — the frame, not the old cushion, whenever the metal is bare. The published Florentine arm-chair pad is 22″ × 18″; if your tape disagrees, your tape is what we cut to. Record to the nearest quarter inch; the order forms take eighths.
Yes — the ten current cushion collections, the icon cast-aluminum lines, and retired classics like Tamiami and Florentine. Specialist charts are our reference; uncharted pieces are routine: your three measurements, one photo, and the block is cut. We are an independent workshop, not affiliated with Brown Jordan.
Test the foam, not the fabric. Press the seat flat and count: if it rebounds instantly and holds its edges, a cover is the cheaper fix. If it stays dished or the edges have gone soft, the foam is done and a cover is money on a dead core. Our cushion covers close with zippers — spot cleaning between washes, and covers remove for washing.
There is no factory chart. The specialist-published reference: Florentine arm chairs 22″ × 18″, chaises 24″ × 77″ (47″ seat / 30″ back), club seats 23″ × 24″ with 23″ × 18″ backs, ottomans 24″ × 25″. Collections differ block by block — the table above lists what the specialists publish, and your own measurements outrank all of it.
From a $45 make-base plus area at per-sq-ft rates: a Florentine club seat block (23 × 24 × 4, 50D foam) estimates at $158, and the specialist routes list the comparable sets at $225 to $412 — useful anchors before you build. Every fabric prices flat, so fabric choice never moves the number.
Made to order in 4–7 business days (3–5 rush when the season is biting), then shipping in 3-6 weeks, roughly half the wait typical US custom shops quote. Straight rectangles run toward the fast end of the window.
Made and shipped by the same hands
- Custom cushion factory for 10+ years — we cut, fill, and sew every order ourselves.
- Before any fabric is unrolled, the measurements you sent are re-verified.
- Nothing is stocked — any fabric, any piece, one cushion or forty.
- Outside ±½″ (±¾″ beyond 36″) on our cut, wrong fabric, or wrong build — remade free of charge.
Brown Jordan seat blocks estimate from $158 (23 × 24 × 4 in., 50D) — four steps to a quote.
We are an independent cushion manufacturer, not affiliated with Brown Jordan or any retailer. “Brown Jordan” and the collection names above are used only to identify the furniture these cushions are made to fit.
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