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
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