Pacman pouf

Step 1Design

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.

Material list:

- 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!

Equipment needed

- workmate / bench
- Jigsaw
- drill
- drill-bits
- countersink
- 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).
- knive
- markers

! 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!

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