Since then, we've used it as a toy box in our family room and it looks like this, overflowing with stuffed animals and looking crappy.
So I made a new lid and cushion, along with a paint job to hopefully make it look like a bench rather than the toy box.
I bought a little 2'x4' sheet of MDF 1/2" thick for the lid/ seat.
I had the guy at Home Depot cut it down to size for my box. I measured 1/4" overhang on the front and two sides.
I chose not to prime. So I just painted 2 coats of semi-gloss white paint. I painted the lid separate from the chest.
3. ATTACH LID
I used a long skinny "piano hinge" that was 1/2" wide on each side, and 30" long. It was $6.50 and worked well to secure the lid to the skinny back wall of the chest.
The directions where to screw the hinges are specific and on the package. Once it's on, it holds the lid up and open, then folds on itself to close. These are awesome and I found I only needed one to hold up the toy box lid. The lid can only open 65 degrees with the hinge, but I thought it was plenty of room to get everything out, plus it prevents the lid from opening to much and hitting the wall behind the chest.
2. CUT PIECES and MAKE PIPING
I measured my foam to know how big to cut my cushion fabric, and added 1" in each direction for 1/2" seam allowances. I cut a top out of canvas, and used scrap denim for the bottom.
For the sides, the same thing, adding 1" for seam allowances. Since my foam was 2" thick, the strips for the sides were 3" wide.
PIPING: To make the piping, I cut the yellow canvas 1.5" wide and sewed them together in one long strip. I measured the perimeter of the cushion and cut a piece of thick cord with a few inches to spare. Next I folded the skinny strips around thick cording, and using my zipper foot sewed the piping in, leaving the first and last 3-4" unsewn.
3. SEW PIPING TO TOP and BOTTOM
Using 1/2" seam allowance with the zipper foot, sew the piping all around the edges of the top and bottom pieces. Leave 3-4" unsewn in the beginning to connect it with the end.
When you get to the end, you need to connect the two pieces. I lay it flat, and take the yellow strips to see where they lay meet, then sew the yellow strips together. Next I trim the cord to match up and just sew it all to the base. Step 4 in this table cloth tutorial has better pictures demonstrating this step to bring the two ends together.
5. ADD SIDES AND ZIPPER
I decided to have a zipper in the back of the cushion side to get the foam in and out. For the back side, rather than cutting a 3" wide strip, you cut 2 strips 2" wide. Then you sew them together, adding the zipper in the center seam. With 1/2" seam allowances, once the zipper is in, that strip should be 3" wide like the rest of the side strips.
Then you just sew the sides to the top piece, meeting the two ends up like the piping.
It goes in our family room right next to our garage door, so I am glad to have a bench to sit on to get shoes and coats on before heading out the door.
So far it's been great, the velcro keeps the cushion where it should be (unless the little guy pulls it off), and the spring lid hinge makes it safe. But the best part is it looks a lot better, and I can hide the toy mess.