DIY Plans to Build the Carlsbad Ottoman

The Perfect Companion to the Chair!

Previously, I posted plans for a new seating collection with the first plan being the Carlsbad Chair. If building the chair, like I am in process of doing, why not build the matching ottoman? The DIY plans to build the Carlsbad ottoman are super-easy and include simple upholstery instructions – if you can sew a straight line, you can sew the basic box cushion for this ottoman! I am still so excited about this collection!

Materials:

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

Lumber:

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

Cut List:

• 4 – 2×2 at 11-1/4″ – Legs
• 2 – 1×6 at 21″ – Frame
• 2 – 1×6 at 28″ – Frame
• 1 – 1×6 at 22-1/2″ – Center Support
• 1 – 3/4″ plywood at 24″ x 31″ – Top

For the Upholstery:

A 1″ or 1-1/2″ memory foam twin-size mattress topper would be perfect to pad the frame of the ottoman. The mattress toppers are quite inexpensive and easy to find.

• Foam to cover the frame
• Spray adhesive – I recommend 3M Super 77 (my favorite!)
• 3-1/2 yards of 54″ wide fabric
• 1 – 24″ x 31″ piece of 6″ foam (I purchase mine on eBay!)
• Hook and Loop tape
• Zipper for cushion closure, optional
• Upholstery tack or decorative gimp (trim)
• Stapler & staples (a pneumatic stapler is fabulous for upholstery!)

Click on the drawings for a larger view!

Step One

Cut the pieces for the legs and the frame. With the pocket hole jig set for 3/4″ material, drill pocket holes in each end of the frame pieces. Attach the frame pieces to the legs using glue and 1-1/4″ pocket hole screws. The outside face of the frame pieces will be flush with the outside faces of the legs.

Step Two

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

Step Three

Cut the piece for the top. Spread glue on the top edges of the frame pieces, legs, and support. Position the top, then secure in place with countersunk 1-1/2″ screws through the top into the tops of the legs, the frame pieces, and the center support.

Finish the legs as desired!

Step Four

Cut a piece of the 1″ or 1-1/2″ foam measuring 31″ x 37″. Spray the top and the longer frame pieces with the adhesive and position the foam. Secure the foam to the underside of the frame pieces, trimming the foam around the legs.

Cut two pieces of foam at 6-1/2″ x 24″. Spray the side frame pieces with adhesive, then position the foam. Secure the foam to the underside of the frame pieces, trimming the foam around the legs.

 

Step Five

Cut a piece of fabric measuring 37″ x 44″. Mark the position for the top and sew or glue one side of the hook and loop tape to the right side of the fabric. The hook and loop tape will attach to the cushion to help keep it in place so that the cover can be washed. Drape the fabric over the foam, folding where necessary (like at the corners), and secure to the underside of the frame pieces with staples. A few staples can be added down the folds at the corners then covered with upholstery tacks or gimp.

Step Six

I have created a tutorial on how to make a basic box cushion. Follow the tutorial to make the cover for the 6″ foam piece. Sew or glue the other side of the hook and loop tape to one side of the cover, matching the position of the hook and loop tape on the fabric on the top of the frame.

As I build the pieces in the collection, I will include photos which will make the upholstery how-to a whole lot easier! If there are any questions about the DIY plans to build the Carlsbad ottoman, leave a comment below or contact me at cher {at} designsbystudioc {dot} com!

Originally posted 2014-09-04 08:00:03.