When I saw the picture on the internet, I thought, well... that shouldn't be so hard to make it my self and dove into the adventure of designing, creating and (for the first time) doing upholstry. I hope you like it and comments/suggestions are welcome...
(please forgive me my poor choice of english words or typos in this instructable, but I think the general idea is there...)
Step 1: Design
First thing I always do when I start a build or a project, I create some Autocad drawings on scale, so in later stage during the build, I can easily measure the angles and sizes of the woodwork I need.
The requirements for the design I constricted myself to:
- low cost (was about €120)
- low weight
- easy to build
- sturdy (should be able to hold 2 people at least)
- in metrics (of course, it is the world standard!)
Then the following process was to determine the size of the pacman:
- for the height I took my current couch as the best height (40 cm). Keep in mind that the foam/padding determines the height of the woodwork!
- the radius of the pacman was defined in proportion with the height. It looks quite large (d=80 cm) but proportionally the pacman will look strange if the height (40cm) was set to a 50 cm diameter.
- 15 mm MDF, depending on the size, you will need at least the C-shape to be created from one piece.
- 9 mm multiplex (plywood)
- 32mm*40mm timber (count number needed * height for total length needed)
- larger ones (for example 40mm*40mm) for the corners and block
- upholstry. I used sky to get that leather-look, but it is not so flexible. Mine had already some sliding-stuff on the inside, so it can slide over the foam. If you get other stuff, inform if you need additional stuff.
- cardboard strips. I had special ones, but you can cut some yourself
- staples.... lots!
- workmate / bench
- screws (about 30mm in length, 3,2*30mm would be ok)
- wood glue (read instructions!)
- needle (curved one special for this type of work) and thread (special stirdy one!)
- sewing machine [if available] (I don't know if a regular sewing machine is able to get through the upholstry)
- foam and other filling
- a stapler! (I had a pneumatic one, but an electrical or whatever is a must... I don't thing the manual ones will be able to enter the MDF deep enough).
! Tips / Remarks
In the design the top (9mm multiplex/plywood) of the pacman was created seperately because I was not certain if the upholstry required a top that was not connected. Only when doing the upholstry I found out that it was better that the top was fixed but also for the weight reduction it is a good solution!