Deck seam with reduced selvage

1. A method of forming a welt within a single sheet of coverstock, the method comprising:

providing a sheet of coverstock, said sheet having a front surface and a back surface;

folding said sheet over upon itself such that a first portion of said back surface overlies a second portion of said back surface, creating a first foldline;

providing a needle and sewing one or more stitches S 1 through said folded sheet, said one or more stitches S 1 located at a distance from said first foldline, creating an extended welt head;

unfolding said sheet;

folding said sheet over upon itself, around said extended welt head such that a first portion of said front surface overlies a second portion of said front surface, creating two overlying second foldlines;

sewing one or more stitches S 2 through said folded sheet and through said extended welt head, said one or more stitches S 2 located at a distance from said second foldlines that is greater than the distance of said first stitches S 1 from said second overlying foldlines;

removing selvage from said sheet by cutting said sheet along a line located between said second foldlines and said one or more stitches S 1 .

2. The method of claim 1 wherein said sheet of coverstock comprises a face layer and a foam backing layer.

3. The method of claim 2 wherein said face layer comprises fabric, leather, a polymer or a fiber-reinforced polymer.

4. The method of claim 1 wherein said sheet comprises fabric, leather, a polymer or a fiber-reinforced polymer.

5. The method of claim 4 wherein said polymer comprises vinyl, polyurethane or polyolefin.

6. The method of claim 1 wherein the welt is formed for an armrest, a headrest, a seat cushion, a seat back, an instrument panel or a roof cap.

7. A method of forming an improved deck seam construction for a welt formed between two sheets of coverstock, the method comprising:

providing first and second sheets of coverstock, said sheets each having a front surface and a back surface and an edge;

placing said first sheet on top of said second sheet with said front surface of each sheet facing the other and with said edge of said second sheet extending beyond said edge of said first sheet;

providing a needle and sewing one or more stitches S 1 through said first and said second sheets, said one or more stitches S 1 located closely adjacent said edge of said first sheet, creating a seam;

folding said edge of said second sheet under said first sheet such that said back surface of said first sheet overlies said front surface of said second sheet;

sewing one or more stitches S 2 through said first and second sheets, said one or more stitches S 2 located closely adjacent to said edge of said second sheet thereby forming a welt between S 1 and S 2 .

8. The method of claim 7 wherein one or both of said first and said second sheets of coverstock comprises a face layer and a foam backing layer.

9. The method of claim 8 wherein said face layer comprises fabric, leather, a polymer or a fiber-reinforced polymer.

10. The method of claim 7 wherein one or both of said first and said second sheets comprises fabric, leather, a polymer or a fiber-reinforced polymer.

11. The method of claim 10 wherein said polymer comprises vinyl, polyurethane or polyolefin.

12. The method of claim 7 wherein the welt is formed for an armrest, a headrest, a seat cushion, a seat back, an instrument panel or a roof cap.