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[sjc <indexer AT fairpoint.net>]

Bev, I was mulling over how to draw a little illustration of a way to 
make your mat cover and it occurs to me now that a good thing to do in 
this case would be to bind the whole thing, as that way when you get the 
inevitable edge wear you can just replace the binding, whereas if you 
stitch the perimeter seams and turn them (in a traditional straight 
seam), the wear will occur on the outside of the seam, and in order to 
take a new seam (to cut off the worn part) you would have to reduce the 
sides too much.

So, here's what I think I'd do (gave up on the illus, not my talent), 
using made-up measurements, of course.  I'll say the finished size is 
about 3X6', and for the sake of this discussion the open end is the 
short end.  I've also allowed wide seam allowances that might not suit 
you, obviously all that's adjustable to suit.
   Cut a front 38X80", and a back piece 38X90".  Bind short edge of 
each piece.  Line up the unbound edges with wrong sides together and 
stitch around them twice, trim near the seam, then bind that seam, on 
the outside, on all three sides.  Bag, roll, and insert the foam all the 
way to the stitched end of the cover 'pocket' (keep the distal end in 
place in the pocket with binder clamps or something, Ron's hands maybe), 
and smooth it all out.  Tuck the longer edge of the back piece over the 
top of the foam so that it's between the upper cover and the foam.  Pin 
that in place, and take the loose end of the top cover to the back, pin 
it down smoothly over all.  Then mark the back piece for your Velcro 
placement, unpin the top flap and mark Velcro placement on that.  I'd 
put the hook end of the Velcro on the back.   Take all the pins out, and 
may have to remove the foam (depends on your working space, manual 
dexterity, and machine throat space)  and stitch your Velcro strips 
down.  Might want to add a little pocket somewhere (I put pockets on 
everything now that there's nobody here to put frogs and dead moles in 
them.) and you're done.

That way it's pretty easy to do, and the part that will wear first, 
edges, is readily replaceable.

SJ