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Custom Closet and Storage Ottoman Karl turns a spare room into a posh dressing suite. From "Wasted Spaces" episode DWSP-206

(Continued from page 2)

Karl teaches Cathrine how to build a custom storage ottoman for the center of her new closet. After cutting out the pieces, they assemble the main frame of the ottoman. Upholstering the top turns this plain box into a stylish piece of storage and seating.

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Building the Ottoman Frame

• Sketch the design of the ottoman – a box with an upholstered top – on graph paper before beginning work. Make sure the piece will be an appropriate size for the space and a comfortable height for seating.

• Using a circular saw, cut the component pieces – top, bottom and sides – from 3/4-inch plywood according to the design sketch. Set the piece for the ottoman's top aside.

  Safety Alert: Always wear eye protection and use caution when using a circular saw or other power tools.
  

  	Figure A
  	Figure B

• Karl's design for Cathrine's ottoman included storage drawers. Cut the openings for these drawers using a plunge cut with the circular saw: Carefully hold back the blade guard and lower the saw into the wood to start a plunge cut. Use a hand saw to cut out the corners. It's also possible to make these cuts by drilling large pilot holes and cutting with a jigsaw, going back to square up the corners.

• Assemble the sides and bottom of the plywood box with wood glue and nails (figure A).

  Safety Alert: Use extreme caution and wear safety glasses if using a power nailer for this step.

• Pieces of 2x4 lumber support the drawer guides. Attach these from the bottom to hide the screw heads.

• Following the design dimensions, build smaller plywood boxes to serve as the drawers. Make the front panel of each box slightly larger than the rest of the piece to create a functional drawer front.

• Attach trim pieces to the inside of the box to support the top.

• Prime and paint the piece, then add drawer guides (figure B), feet and other finishing hardware. Now, the ottoman is ready for an upholstered top.

This comfy ottoman does double duty as a storage hideaway.

Upholstering the Ottoman

• Measure and cut a piece of 3-inch foam to fit the plywood top for the ottoman. Glue it in place and let the glue dry.

• Cover the work surface to protect the upholstery fabric.

• Lay out the fabric, right side down, on the work surface.

• Carefully position the ottoman top, foam side down, on the fabric.

• At the center of one of the sides, pull the fabric around the foam to the plain side of the plywood and staple in place. At the center of the opposite side, pull the fabric taut and staple in the same manner. Repeat the process at the center of each of the remaining sides.

• With all four sides tacked into place, continue stretching the fabric and stapling it to the plain side of the plywood. Alternate sides, making sure to pull the fabric tight before stapling. Avoid any creases in the fabric.

• At the corners of the piece, fold the fabric neatly around the corner as though wrapping a present. Staple in place.

• Once the entire piece has been stapled, trim away any excess if needed. The ottoman's cushioned top is now ready for action.

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RESOURCES :

Hand Tools
Klein Tools
Website: www.kleintools.com

Paint
Bearden Decorating Center
Website: www.benjaminmoore.com

Table Saw
Delta Tools
Website: www.deltaportercable.com

Power Tools
Porter-Cable Tools
Website: www.deltaportercable.com
Delta Tools
Website: www.deltaportercable.com

Closet Storage System
Closetmaid
Website: www.closetmaid.com