DIY Network

Reupholstered Ottoman Reupholstered Ottoman From "Trade School" episode DTRS-112

Figure A

In this opening segment, follow along with upholstery student Shanna Vigil as she's challenged to reupholster a hand-me-down ottoman (figure A). The ottoman is in great condition, but Shanna feels the fabric style is outdated. To prepare for the industry-speed standard, she attempts to complete the project in one class period -- a personal record. Additionally, the process is "sewing intensive," which may work against her ....

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Basic Tools:

Cloth measuring tape
Shears
5" curve needle
Tack hammer
Staple remover
Nail puller
Sewing machine
Steamer

	Figure B
	Figure C

• Shanna begins by naming and labeling the various pieces of the ottoman. She writes these pieces into a notebook, which serves as the "roadmap" of her project (figure B). This project has only three pieces to inventory: the top, the boxing and welt cord or piping.

• Next, she measures the three pieces on the ottoman and writes these figures into her notebook (figure C). She adds two inches to each measurement. With these dimensions, she determines the total amount of fabric she needs. She also notes which pieces will be sheathed in muslin. Muslin is a thin cotton fabric, similar to bed sheets, that serves to contain the shape of cotton batting and reduce wear on the final fabric. Because the top piece and the boxing contain cotton, both pieces require muslin.

• Shanna also uses her notebook to record which pieces need to be patterned and shaped. This means any piece that requires sewing and has curves. She determines that the top piece is the only one that will be patterned and shaped.

• With her inventory complete, Shanna starts cutting the muslin (figure D). Using her measurements, she marks and labels the sheet of muslin in chalk and cuts the shapes out. She pins the top sheet of muslin on the ottoman and rubs chalk around the existing welt cord to trace onto the muslin (figure E). She also traces the muslin pieces to paper for later reference.

Figure D

Figure E

• Then, Shanna begins joining muslin top to the muslin boxing using an industrial sewing machine (figure F).The term "boxing" refers to the sides of the ottoman. Once sewn together, she tests the fit over the ottoman (figure G).

Figure F

Figure G

• With the muslin cover complete, Shanna strips the ottoman (figure H). She removes the staples from the bottom of the ottoman and removes the fabric, cotton, foam and cambric layer. These innards are in good shape, so she recycles them for later use. She continues to strip the ottoman until only the wood frame and springs remain.

• Shanna builds up the ottoman by first tying the springs (figure I). She measures the dimensions of the frame and cuts nylon string to these measurements. She tacks the springs to the frame and ties knots along the length of each spring. This ensures that all the springs act in unison, which strengthens the integrity of the ottoman.

Figure H

Figure I

• Next she measures and cuts a sheet of burlap that acts as a barrier between the springs and the foam, which comes later. She folds the edges of the burlap and tacks onto the frame (figure J).Then she hand-stitches the burlap to the springs using a curved needle (figure K). This further strengthens the ottoman by creating unison between the springs and the burlap.

Figure J

Figure K

• With the burlap securely in place, Shanna returns the recycled foam insert by injecting steam into it (figure L). Over time, the foam tends to compact and by steaming it, it regains its original shape. She sets the restored foam on top of the burlap.
  
  
• She then builds up layers of cotton batting on top of the foam insert (figure M). Once the desired height and shape of the cotton is achieved, she covers the ottoman with the already-sewn muslin sheath.

Figure L

Figure M

• Next she tacks the muslin to the frame on the bottom of the ottoman. She only pounds halfway in so that she can pull the tacks to adjust the shape of the cotton. Once the ultimate shape is achieved, she drives the tacks fully, leaving four-inch spaces near the legs. She snips the muslin near the legs so it can be pulled together underneath and tacks the spaces. She tucks the flap of muslin up under the leg (figure N).

• Shanna chooses to cover this ottoman in a soft, cream-colored fabric. She utilizes the paper patterns she created in the muslin stage by tracing and cutting the pieces accordingly.

• She first crafts the welt cord by sandwiching cotton piping in a long strip of the fabric. Using the sewing machine, she folds the fabric over the piping and stitches it (figure O). She trims the welt cord to half-an-inch wide.

Figure N

Figure O

• After the trimming is complete, Shanna sews some of the welt cord around the edge of the top piece of final fabric (figure P). She carefully walks the machine around the corners to avoid any gaps. At the meeting point of the two ends, she cuts the cord so that it overlaps at one inch. Then, she peels back the machine stitching and clips the piping ends so that they butt together. The fabric is then folded and stitched creating a uniform line (figure Q).

Figure P

Figure Q

Now Shanna is ready to sew the boxing fabric to the top piece and welt cord -- again, carefully maneuvering around corners to avoid gaps. Once the pieces are completely sewn together, she lays the sewn fabric over the muslin on the ottoman (figure R).
• She tacks the final fabric on the bottom side of the ottoman, again leaving four-inch spaces by the legs. She snips the fabric vertically up the leg and tucks the flap under. Then she finishes tacking in the spaces. Then she tacks the remaining welt cord along the bottom of the ottoman (figure S).

Figure R

Figure S

• For the finishing touch, Shanna tacks a sheet of black cambric to the bottom of the ottoman. Cambric is a filmy fabric with a texture similiar to that of dryer sheets, only thicker. After folding the cambric under at the corners, she tacks it in place (figure T).
• The final reward is a beautifully upholstered ottoman that Shanna displays proudly and prominently in her home ... though her cat has decided it makes a better daybed! (figure U).

Figure T

Figure U