The Neverending Project

I started this redo project a few weeks ago (okay, maybe a couple of months is more accurate), and it seems to want to continue for the rest of eternity. Some friends of mine were paring down their crowded backyard, and offered up a patio set. Not one to turn down a project (or free fun things), I accepted the gift(s). One patio table with a glass top, and four fabric-backed chairs.

It seemed easy enough: Repaint said furniture, purchase and sew new fabric backs and seats. The painting was the easy part. I just lightly sanded the surfaces, to make sure the paint would stick. And spray paint and I continued our love affair.

The sewing, however, is another story. I got super-lucky with the fabric. It was on the "remnant/ sale" table in the verrry back of the store, and found this outdoor fabric. Originally something like $26 a yard, I got it for $6 a yard.

I originally purchased cording that would be sewn into the edges of the back and bottom panels, then slid into channels that would be screwed on to the chairs and secured in place. After finishing all my sewing, I went outside to grab one of the channel pieces, and BUSSST. The cording was wayyy too small and immediately slipped out of place. Back to the store for round two.

Round two, with larger cording, was an immediate bust as well. Third time's the charm, right? I sewed in the largest cording Joann's had (1mm, I think?), and reassembled the chairs. VIOLA! I even tested them out. Perfecto!!

Cue the arrival of friends and dudes, who apparently weigh more than I do. (I am certainly not complaining about the fact that I weigh less than dudes.) Also cue the immediate bust of the chairs. AGAIN. But seriously. Look how cute this is? I grabbed the beach umbrella, planted some succulents in the mason jars, and instant party!

I'm at a loss as to how I should fix this?! Does anyone have ideas? I've thought of rubber tubing (the kind that is used for screen doors), or wooden dowels. Suggestions?

I need help.