Instructables
Picture of Full Metal Sofa
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Hi There,

so this is an little more complex project,
I was looking for an new sofa but i couldnt find anything i like, and i´ve never seen an sofa completly made of Metal.
so I got the idea to DIY an FULL METAL sofa and thought it couldnt be that hard to do, some profile tubes, a little sheetmetal, welding...done.

It costs me a week,

but you can do better and avoid some of the errors that I made.
It is not an complete step by step Instructable, i lost some of the pics of cutting the tubes, but i think its comprehensable.

At first i had to say this needs some skills in Metalworking and welding.

-Mesure up:  Make a Sketch, think about which place the sofa should stand.
                        Think about the dimensions of the sofa, the angle to the back, the seating hight and depht.
                        this costs me most of the time, i changed often (as you can see in my sketch)
                        Make a material list.

-Material:      For the tubing i choose 40x20millimeter square tube, wich is strong and cheap.
                       The sheetmetal is 1,5millimeter stainless steel.

-Cutting:        Use your material list and sketch and cut the tubes you need.
                        usefull is an electric chop saw, it´s easy, exact cutting and you will get an 90° angle without hone down.
                        check the parts and measures with your list and sketch.

 -welding:      ( Sorry not so much pic´s)
                        you will need an stable, big enough and fireproof working table, on wich you can fix the parts and tubes with                                         some visegrips or simmilar tools, for the tube to tube welding i use some magnetic angles to fix it in right position.
                        I used an standard MAG 250 Amp. 1 millimeter wire, welding machine wich i narmaly use for car repairs it got´s    
                        enogh power for that tubes.
                        At first do only a little tackweld on every corner, now you can che again the angles and measures before welding it
                        through.
                        Be careful, welding can be dangerous.

-Grinding:      first i grind down the welds roughly with an flex.
                        than i use an oscilating sander with an 180 abrasive.
                        nearly all of the welds are in the visible area so you need to do an good surface.

   -Finish:        so i gave the whole frame to the sandblasting and it gets an clear powder coating wich brings these nice
                        antracite effect.

-Paneling:      The seat is an piece of stainless steel 1,5millimeters, i gave it to bending cause i´ve got not the right tools to do that
                         job.
                         same with the backrest.
                         note: you have to measure up really exact the frame before doing the sheet metal, maybe the frame got´s an little
                         delay after welding.

assembling:  i riveted the sheet metal to the frame, thats very easy to do and fast.
                         Drill an hole thrugh the sheet metal and the frame ( in the matching diameter, depending to the  rivets you use)
                         tighten with the riveter.
                         be sure there is no sharp edge on top of the rivets.

 -Cushion:      I didnt really know wich foam to use so i called an foamdealer and ask him wich is best for my project.
                         he send me an relative tight one, thats ok i like it.
                         I cut in six parts for a nice trifucated look.

-upholstery:   The Problem!
                          DOES ANYBODY KNOW AN GOOD CUSTOM UPHOSLTERER NEAR BERLIN???



 
hope you like it.

What is in the download?

Falkenberg (author)  kyndra.watson19 days ago
Hey there,

There's Not much measures in the download, and no 3d Sketch, sorry.
Greatings from Berlin

Seb.
psauvignac made it!10 months ago

On my way to make mine.

Need one tube to weld but no easy to cut with the angle.

Was my first time welding, interesting to do :)
Now i need to find the metal sheet and I will buy brown leather pillow ...!

Thank you for the idea !!

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Falkenberg (author) 11 months ago
The Tubes are 40x15x2mm.
psauvignac11 months ago

Hey ! very good sofa :)

What is the thickness of your tubes?

This is how much this post has inspired me!!!

I made a couch a chair and a coffee table that matches... the coffee table actually pushes up next to the couch so you can lay the futon mattress down flat and have a bed.

Thank you very much for the inspiration!!!!
TOP NOTCH INSTRUCTABLE!!!
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also... do note... that the chair doesnt have much for cusion on it yet... cuase this instructable didnt go into detail on that... hahahahahahaha but i have figured something out... will send pics of you are curious how to make a cusion when i am done... might make an instructable on it.
wow nice job on the sofa and besides this is so much easier to make then having to buy one and thanks falkenberg
Casarini1 year ago
Ótimo trabalho. Parabéns.
Good job!! Now we just need a full metal.... Jacket!!!

Sorry for the terrible pun.
lbilharz1 year ago
good upsolstery in berlin can be found here: http://www.schaumstoffladen.de/index.htm
Gadisha1 year ago
P.s. does it come with a jacket? ;P
Gadisha1 year ago
Cozy? ;)
Just kidding, it looks great!
belsey1 year ago
If you can make this frame, you can make the pillow cushions yourself too, it's not that hard providing you have or can borrow a sewing machine.... These are simple squares, and zippers aren't that hard to sew either.
Now this is an appropriate couch for the apocalypse.
prestux1 year ago
Love it!, this would look good anywhere, but would make a particularly fine addition to any industrial-themed ManCave.
wait.. Berlin? are you in Germany by chance? is that why there's a 'berg' in your name?
jarikcbol1 year ago
its pretty, and very well made, but it looks stunningly uncomfortable to sit on. Hopefully I'm wrong, and its like sitting on a cloud.
flavrt1 year ago
Awwww, the cushions destroyed your hard-ass cred. But there is a chance to redeem yourself. Get rid of the fluff and upholster the sofa with 5 cm thick slabs of maple.

Just kidding. It's glorious. Functional art is the highest art.
Nicely done!
Nice work!
knife1411 year ago
WOW! What nice work! Thanks for posting this.
That is a sweet frame! Looks much more comfortable with those cushions on it ;)