DIY Plans to Build a Carlsbad Chaise

Another Piece Added to the Carlsbad Collection – the Chaise!

I am still so excited about the Carlsbad collection! So far, we’ve covered the chair, the ottoman, and the sofa, and now we are covering the DIY plans to build a Carlsbad Chaise. The chaise is by far one of the easiest pieces to build and upholster, and I may be adding it my own collection! The chaise can be built and upholstered in a weekend!

Materials:

• 1-1/4″ pocket hole screws (<– affiliate link!)
• 3/4″ screws
• 1-1/4″ screws
• 2-1/2″ screws
• Wood glue
• Sandpaper (100, 150, 220 grits)
• Finishing supplies (primer & paint, or stain, sealer)

Lumber:

• 1 – 1×4 at 4′
• 1 – 1×6 at 8′
• 3 – 1×8 at 8′
• 1 – 2′ x 4′ sheet of 1/4″ plywood
• 1 – 4′ x 8′ sheet of 3/4″ plywood

Cut List:

• 2 – 1×8 at 61-1/2″ – Base Frame
• 2 – 1×8 at 31-1/2″ – Base Frame
• 4 – 2×2 at 11-1/4″ – Legs
• 3 – 1×8 at 30″ – Supports
• 1 – 3/4″ plywood at 31-1/2″ x 63″ – Deck
• 1 – 1×6 at 31-1/2″ – Back Frame
• 1 – 1×4 at 31-1/2″ – Back Frame
• 3 – 1×6 at 14″ – Back Frame
• 1 – 1/4″ plywood at 15-5/8″ x 31-1/2″ – Back

For the Upholstery:

The entire frame will be covered with 1″ foam and fabric. The back cushion will be made with 4″ foam, and the seat will be made with 6″ foam. I like to purchase the high-density foam for cushions on eBay. A  1″ foam mattress topper will be much more economical to purchase for padding the frame.

The seat cushions will measure approximately 31-1/2″ x 57-1/4″ and the back cushions will measure approximately 19″ x 31-1/2″. I have written a tutorial on how to make a basic box cushion that is easy to follow and requires minimal sewing skills.

• Duct tape
• Spray adhesive (I recommend 3M Super 77 – it is the best!) (<– affiliate link!)
• 8 yards of 54″ wide drapery fabric, canvas, or cotton duck
• 1 – Twin size 1″ foam mattress topper
• 6″ foam at 31-1/2″ x 57-1/4″”
• 4″ foam at 19″ x 31-1/2″
• 2 – 48″ upholstery zippers or hook and loop tape
• Contrasting thread
• Stapler and staples (if you have a pneumatic stapler, that would be best!)
• Upholstery nails or decorative gimp (trim)

Step One

Cut the pieces for the frame. With the pocket hole jig set for 3/4″ material, drill pocket holes in each end of the longer pieces. Assemble the frame as shown using glue and 1-1/4″ pocket hole screws.

Step Two

Cut the pieces for the legs. Secure the legs to each corner of the frame using glue and countersunk 2-1/2″ screws from the outside of the frame into the legs. The top of one end of the legs will be flush with the top of the frame.

Step Three

Cut the pieces for the supports and drill pocket holes in each end. Secure the supports to the frame as shown using glue and 1-1/4″ pocket hole screws.

Step Four

Cut the piece for the deck. Secure to the top of the frame using glue and countersunk 1-1/4″ screws. Make sure to pre-drill the holes – this will keep the frame from cracking or splitting!

Step Five

Cut the pieces for the sides of the back. Cut the angle using a jigsaw, a bandsaw, or a tapering jig on a tablesaw. Drill pocket holes in each end.

Step Six

Cut the remaining pieces for the back frame and assemble the frame using glue and 1-1/4″ pocket hole screws.

Position the back frame on the back edge of the seat. Secure the frame to the seat using glue and 2-1/2″ screws. The screws will be positioned through the bottom of the frame into the back edge of the seat frame, and also through the front edge of the frame into the support closest to the back of the seat frame.

Step Seven

Cut the piece for the back. Secure the back panel to the back frame using glue and 3/4″ screws.

Finish the legs as desired.

To Upholster the Chaise:

Cover all of the edges of the plywood using duct tape. This helps soften the sharp edges so that they don’t cut through the foam and upholstery during use.

Spray the entire frame with spray adhesive and apply the mattress topper covering the sides, the foot of the frame, and the top of the back. Trim the mattress topper as necessary.

Cut a piece of fabric measuring 50″ wide by 66″ long. Cut another piece of fabric measuring 50″ wide by 32″ long. Cut a rectangle out of the lower edge of the fabric as shown leaving “tails” on each side. This portion will cover the part of the frame that the seat fabric will not cover. Stitch the center of the back fabric to the seat fabric as indicated in the drawing, leaving the “tails” and the remaining part of the seat fabric free.

 Drape the fabric over the padded frame, securing in place with the staples. Pull the fabric taut and fold in the corners as necessary. The seam will be positioned where the back meets the seat.

Cut a piece of fabric at 25-1/2″ x 34-1/2″. Press a 1/2″ seam allowance in each edge. Secure to the back of the frame (to cover the opening) using staples. Cover the staples with decorative gimp.

To Make the Cushions:

Follow the tutorial on how to make a basic box cushion to make the cushion for the seat and the cushion for the back.

The chaise is really easy to build and the upholstery is even easier but hard to explain… So sorry, I did my best! If there are any questions about the DIY plans to build a Carlsbad Chaise or the upholstery, leave a comment below or contact me at cher {at} designsbystudioc {dot} com!

Originally posted 2014-09-23 08:00:15.