Step 1: You will need
The ottoman in this project is 500 x 500mm wide and 400mm high. You can easily adjust the width measurement to make a larger ottoman.
1 of 16mm BisonBord 500 x 500mm
2 of 16mm BisonBord 200 x 500mm
2 of 16mm BisonBord 200 x 468mm
1 of 1,8 metre PAR pine 44mm wide
Pack of 16mm screws
Pack of 4 x 40mm smooth shank cut screws
Piece of high density foam 100mm thick
and 500 x 500mm - if you can’t find 100mm
thick foam, use two pieces of 50mm thick
4 feet - or make your own with blocks of pine
Drill/Driver plus assorted bits
Staple gun and 6 or 8mm staples
Step 2: Assemble the base
Make sure you place the screw tip in the exact centre of the hole in the brace, or it will not be straight.
Step 3: Adding the sides
Make sure to leave enough room for mounting the foot battens below.
Step 4: Attach the feet battens
These will be support battens for the feet. If you are adding larger feet you will need a wider batten.
Screw the battens in place through the outside using 4 x 40mm smooth shank cut screws.
Step 5: Cut the foam for the cushion
To cut to size I placed the base on top of the foam and used a sharp (new blade) craft knife to cut to size.
The foam is only 5cm thick, so I am cutting two sections of the same size for a thicker top.
Step 6: Add batting
Using the staple gun, staple down only the side edges of the cut batting.
Step 7: Cut and attach top fabric
Place the fabric on top of the base and, starting at one side and about 1 cm from the top, staple down. I started on the long edge of the striped pattern to ensure the stripes came out perfectly straight.
Tuck each corner over and fasten down with a staple. This gives the corners a nice, neat edge.
Step 8: Staple top fabric and add side fabric
At the starting point I stapled down the edge of the fabric as shown. After pinning the fabric to the top edge and ending at the starting point, I turned the fabric under and pinned in place. This will be hand sewn once finished stapling.
Step 9: Staple fabric to box frame
Leave corners until last so that you can tuck and fold neatly before stapling.
Step 10: Add upholstery strip to finish box
This strip is made of soft metal and comes in strips of 1 metre long.
You hammer in upholstery pins in blank holes on the strip to fasten down. Amazing!
The strip hides the join between the top and side sections of the fabric.
Step 11: Make the ottoman cushion
I bought ready-made legs at my fabric store and these are screwed into the battens underneath.
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