How to Replace a Broken Zipper on Outdoor Cushion Covers

Zippers on outdoor furniture are the first components to fail because of constant exposure to sun, moisture, and salt air. When the metal teeth corrode or the slider stops locking, you do not need to replace the entire cushion or even sew in a new length of tape. Most outdoor zippers are made with heavy-duty polyester coil, meaning the slider is usually the only part that actually breaks. Restoring your cushions is a simple matter of extracting the old slider and installing a fresh, marine-grade replacement. Done well, this repair will last through several more seasons and save you from the expensive chore of custom upholstery. If the fabric tape itself is shredded, however, you will need to replace the entire zipper track, which is a more involved sewing project.

1. Snip the bottom stop clean. Locate the metal or plastic stop at the bottom of the zipper track. Use a pair of wire cutters to snip the stop off, being careful not to damage the fabric tape.
2. Free the broken slider. Pull the old slider down to the open end of the track. Slide it completely off the coil to clear the path for the new hardware.
3. Align and seal the track. Ensure the two sides of the zipper coil are aligned side-by-side. If the coil is frayed, trim the edges with sharp fabric scissors and apply a tiny dab of clear fray-check liquid.
4. Lock in the new slider. Feed both sides of the zipper coil into the back of the new slider simultaneously. Push the slider forward until it catches both tracks and moves smoothly.
5. Glide test the mechanism. Move the slider up and down the track several times to ensure it engages the teeth fully without sticking. If it sticks, check for debris or bent teeth inside the coil.
6. Secure the bottom stop. Crimp a new metal zipper stop onto the bottom of the track using needle-nose pliers. Ensure it is secured tightly so the slider cannot run off the end again.