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By jjubeck18
#6383
Long story short... I purchased an ottoman from a furniture store and was incredibly disappointing at how cheap the quality was so I decided to build one myself.

I cut 2 40" diameter circles out of 3/4" plywood and then assembled the body using 32 1"X2"s. Lastly I wrapped the body in 1/8" masonite. As it stands, the ottoman is 14" tall and my intention is to 4" thick high density foam on the top to give me a final upholstered height of about 18".

This is where I am getting stuck. I am going to order the foam cut to size. Do I order the foam cut to the exact diameter of the body? Or because I will need thin foam covering the body, 1/4" if I can find it but most likely 1/2", do I order the top foam cut oversized by 2X the body foam thickness? To me this doesn't seem correct because I am thinking that the body foam will be less dense than the top foam and I am imagining this will create a mushrooming effect when upholstered. One additional way that might work is if I order the top foam cut to the exact diameter of the body and then for the sides, wrap the thin foam around the body running from the bottom of the base to the top of the top foam.

I welcome any feedback that you can provide! Thank you.

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By John
#6386
Hi @jjubeck18! What a cool project! Very nice craftsman ship.

I would go about wraping that piece like this. make the 4" top foam the same size as the frame. Then wrap the sides with 1/2" or thicker foam and bring that foam to the top of the 4" foam covering the seam. This will make a smooth transition once you install the cover. 1/4 will be to thin and you will risk seeing the frame edge once your cover is pulled tight.

Hope this helps!

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