Disclaimer: This is the first sofa that I have ever built and have attempted to upholster. I am not a professional. I have done a lot of research and have built what I believe to be a quality piece of furniture. I hope this instructable inspires you to attempt your own build.

*** Update 01/02/2011 : I added some more upholstery pics. The springs are now tied and covered with burlap and foam. Tomorrow I will finish upholstering the chaise hopefully, except for sewing the cushions.

*** Update 12/20/2010 : I began to upholster the arm of the chaise today. I will update this instructable with the upholstery section when I am complete. Until then please see the pictures below. Remember this is my first time trying to upholster so be kind.

One of the hardest parts of searching for furniture is finding exactly what you want. You may find the design that you like, but it has the wrong fabric. Or you find the right fabric but the wrong design.

If you do find what you want, it is completely out of your price range. The solution is for you to build it yourself. I have built a sectional from scratch. I consists of two end Chaise Lounges and a middle sofa with no arms.

These are the instructions to build the chaise that will attach to the sectional. I will post the sofa section later.

I will soon post my upholstery instructable for this sectional soon.

Dimensions: 3 ft. (L) X 5 ft. (W)

Total Cost: about $100 - this cost can be reduced dramatically if you use lower quality material such as construction plywood or MDF and pine wood stock. I chose to use better material so that this furniture will last against my children.

Parts:
     36 linear feet of 1" X 2 1/2" wood stock (I used Poplar)
     18 linear feet of 1" X 1 1/2" wood stock (Poplar again)
     1 - 4' X 8' sheets of 3/4" plywood (I usedcabinet grade Birch Plywood)
     Wood Glue
     Pocket Screws

Tools:
     Tablesaw - ( I have a craftsman 10" )
     Jigsaw - (Only if you are going to make curved arms)
     Orbital sander - (Only if you are going to make curved arms)
     Miter Saw (Chop saw)
     Measuring tape
     Clamps (Really helps when you are working by yourself)
     Pocket Hole Jig ( or your own preferred joinery)
     Rafter Sqaure (triangle)
     Coping Saw

Cut List:

Part Name     |     Quantity     |     Stock Size     |     Stock Length
C -1                           4                        1" X 2 1/2"             23 1/4"
C -2                           1                        1" X 2 1/2"             47 1/2"
C -3                           4                        1" X 2 1/2"             34 1/2"
C -4                           2                        1" X 2 1/2"             29 1/2"
C -5                           1                        1" X 2 1/2"             27"
C -6                           1                        1" X 2 1/2"             22
C -7                           6                        1" X 1 1/2"             34 1/2"
C -8                           1                        1" X 2 1/2"             21 1/4"
C -9                           1                        1" X 2 1/2"             10"

Plywood cutlist 3/4" - 4' X 8' sheet
Part Name     |    Quantity     |    Stock Dimension (W)     |    Stock Dimension (H)
C -a                            1                                  30"                                            9"
C -b                            1                                  23 1/4"                                     9"
C -c                            1                                  59 1/4"                                      9"
C -d                            2                                  27"                                            12"
C -e                            1                                  18"                                            12"
C -f                              1                                  28 1/2"                                      5"

Step 1: Design

The first thing that I need to do was look for the right design. I looked thoughout the internet and at stores to determine what I wanted. Once I got the right design, I determined the overall dimensions of the sofa. The wall that it will go on is 12' wide. I wanted it to stretch the whole length of the wall to provide the most seating possible.

I drew out the design and checked with the wife for feedback. She approved....LOL.

I drew out each section of the sofa and the individual pieces to get a better look at what I will be building.

Step 2: Build Chaise Arm

Parts needed:
Part Name     |    Quantity     |    Purpose
C - 3                            4                         Pieces of poplar for the arm rails
C - 7                            6                         Pieces of poplar for the arm rails
C - d                            2                         Arm Face

I pocketed holed all the ends of the rails.

*** Note : Use glue where ever wood touches wood. You will be thankfull you did, trust me.

**--------------------------------------------------------------------**

I first drew the arm face design on a 27"(H) X 12"(W) piece of plywood. I then cut out the piece with a jigsaw. When cutting out the design, cut about an 1/8" away from the line of the design. You will refine this line with the orbital sander. I used 80 grit sandpaper and I sanded it to the line to get the exact shape that I was looking for.

I then placed the finished arm face on the other plywood to get an identical arm for the rear facing arm face.

Step 3: Build Deck of Chaise

Parts needed:
Part Name    |     Quantity     |    Purpose
C - b                            1                        Outside side deck panel that attaches to outside profile
                                                               of arm
C - a                            1                        Front deck panel that attaches to Outside deck
                                                               and Inside deck panel
C - c                            1                        Inside deck panel that attaches to Front deck panel and
                                                               rear horizontal lower support
C - f                             1                        Deck center support brace
C - 1                            2                        One attaches to Outside deck panel and the other is
                                                               the rear horizontal lower support
C - 5                            1                        Attaches to the Front deck panel
C - 2                            1                        Attaches to the Inside Deck panel
C - 9                            1

Once the arm is built, you can begin to build the deck of the Chaise.

First attach the Side Chaise rail to the front of the arm face. Then attach the stinger board to the inside of the Side Chaise rail. Anywhere that wood touches wood there is glue.

Attach the front Chaise rail face to the sides and attach the side Chaise rail to the front. You are basically just building a box.

Attached the rear rail ( Part C - 1 - 1" X 2 1/2" X 23 1/4") to the Side Chaise rail and the rear face of the chaise arm.

Step 4: Build Back Support

Parts needed:
Part Name     |    Quantity     |    Purpose
C - e                             1                      Inner back support panel
C - 1                             2                      Lower back support rail and rear deck support rail
C - 4                             2                      Rear horizontal upper support rail and Rear Top
                                                              support rail
C - 6                             1                      Back support vertical rail
Extra Piece cut out from the arm panel that I mentioned earlier

Back support is 18" high and 12" wide. The top edge is 2 1/2" wide and is diagonally cut to the bottom edge of the plywood piece to get the right angle. Attach to rear of the chaise side rail.

Attach the bottom rail of back support (C-1) to the Inner back support panel (C-e) not the Inner deck panel. Attach the other side to the arm. This is where the back fabric will attach to. Also it sits partially on top of C - 2.

Attach the Rear deck support rail (C-1) to the Inside deck panel 6" from rear and the top of the stock is 7" above the bottom. This is where the deck fabric will attach to.

I used a clamp on the outside of the arm and the Back support panel to maintain the the 36" distance. I then placed the Rear Horizontal Upper support rail (C-4) on the inside of the back support panel 3/4" down and pressed it against back of arm. I traced the curve of the arm to get a snug fit. I cut this out with a jigsaw.

I also added a vertical support rail against the back support panel (Piece not shown). It is 21 1/4" out of 1" X 2 1/2" stock.

I installed the Top Support Rail (C-4) to the Back support panel, the rear horizontal upper support rail and the arm. Dont worry that this doesnt connect to the arm, we want a gap so that the foam and fabric will fit in between the arm and the back support.

Place part C - 6 against the back support horizontal rails and the Top support rail. Use a rafter square to transfer the angle to the board. Use the miter saw to cut. Mine was about 28 degrees.

You will need to back cut the top of Part C-6 about an 1" inorder for it to fit snug. Install bottom of part about an 1 1/2" away from arm. You may want to add more space depending on the thickness of foam that you plan on using.

Take the extra piece left over from cutting out the arm and with a coping saw back cut the inside curve of the piece. You may want to remove a little bit more off the top length depending on the thickness of the foam you use. I used 2" foam and it was an extremely tight fit.

All done... you are ready for upholstery.