Recently my roommate and I moved into an apartment. We both lacked any furniture so we had somewhat of a shopping spree at the local IKEA. So with all that new furniture came lots of boxes. However, a box from IKEA does not equal the fun large box of my youth. They are flat and kinda boring. But as we was obviously in need of some furniture I thought it would be good to reuse all that material to get a free piece of furniture. Not just any piece of furniture though& a chaise lounge! Chaise lounge is kinda long and it feels funny to say it so we'll stick with "couch" in this Instructable.
In this Instructable we'll show you how to make a very solid piece of cardboard furniture. The basic components of the couch are a few large frame pieces that form the sides. These frame pieces hold the heart of the support, the cardboard beams. The beams are slid into slots that are cut out of the frame. Some cardboard padding/shims are positioned within the internal section of the couch, and then a nice long sheet is adhered to the top of the couch. After all that hard work you'll probably need to sit back and relax... on your new couch!
Step 1: Gather materials
Acquire lots of cardboard.You should ideally find several large flat boxes to use for the outside frame sheets of the couch. The boxes we used came from two bookcases, two desks, a small kitchen table, a bed, a coffee table, and some miscellaneous boxes we borrowed from friends. However, you can make due with lots of small boxes as well, though a few large pieces is recommend.
Hold on to any large pieces of styrofoam that come with the boxes. A packing tube can also be useful too. They can be used for internal supports. Finally, our design does use some tape. We tried to minimize tape as much as possible but some is useful in some sections. So have some packing tape and some double sided tape ready for the steps at the end.
See the schematics below for an illustrated guide but here is a parts list for the final couch:
6 frame sheets: 57.0 x 28.0 (in) sheet per frame sheet.
1 cover sheet: ~70.0 x 20 (in) sheet.
1 bottom sheet: 57.0 x 18 (in) sheet
12 front beam sheets: 20.0 x 5.0
12 2nd beam sheets: 20.0 x 10.0
12 3rd beam sheets: 20.0 x 12.5
12 4th beam sheets: 20.0 x 12.0
12 5th beam sheets: 20.0 x 7.0
8 6th beam sheets: 20.0 x 10.0
12 7th beam sheets: 20.0 x 18.0
16 back beam sheets: 20.0 x 23.5
Lots of scraps and small bits of cardboard