Here's some insight into how upholsterers answer the question about whether to re-upholster a recliner. This is a 2004 thread from a discussion board:
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To upholster or NOT!!! I'm a drapery gal, but I have a recliner that needs to be reupholstered. It has those puffy attached arms, back and seat cushions that I'm sure you all just love, but the thing is so comfortable. It's a Sealy so it's pretty good furniture and it is structurally still in such good shape. The question is...in ya'lls professional opinion, should I have it reupholstered OR should we just buy a new recliner? It is currently leather, but we didn't want to spend the money to have the sides and back in leather when we bought it. The vinyl is tearing where it is stitched to the leather which is the reason it looks so tacky. Thanks for the advice.
My first question would be how does the mechanism work?
Most recliners are cheaply made but I've seen some that are definitly worth reupholstering. If the mechanism works good, yes it sounds like worth redoing. Older ones are certainly worth more than the newer ones from my experiences.
Next question would be, are you going to do it yourself or are you going to hire somebody to do it?
There are upholsterers and there are those who call themselves upholsterers. In my opinion, if you're not going to do it yourself, find a quality upholsterer, somebody who's trustworthy and does good work, quality costs, it may cost you what you paid for it or more, but you'll have something better in the end (maybe even leather back and sides).
But in answer to your question, new or recover? Labor in the $500.00 range and 165-180 sq. ft. of leather or nine to ten yards of fabric needed.* You do the math.
Have all seams (if using leather) top stitched and specify HR seat foam.
Not too many factories will be able to match that quality and the workmanship of a good custom upholsterer.
When people call me about recliners, my line is Lazyboy is probably having a sale. One of the big things with reupholstering recliners are to be very careful not to torc the workings. If they get bent or off kilter, they never work the same. The other thing is to be very careful of hand placement when working on them. One of my employees caught her hand in the workings and it was scarey getting it out. She ended up with a nice bruise.
the best way to discribe reupholstering a recliner is a giant puzzle.
If it's a scissor mechanism, my rule is to not reupholster. Too many things can get wacky. (Especially on the big boy recliner like you describe.) Lazy Boy is almost always worth recovering, and won't slap you with any mechanical surprises or glitches. I just looked at one the other day that was a Flexsteel, but it was a dainty model, like a petite wingback, those usually go ok.
Which confirms my suspicion that it's probably the whole mechanism thing that makes them turn the job down. But if you're willing to pay -- and possibly if you're willing to accept the fact that the mechanism might not be the same after re-upholstering -- then they might take the job.