Hello, I want to make this style sofa on a really tight budget. Could
you help me answer some questions about the design of what is pictured
here? http://www.dellarobbiausa.com/produc...ofa/zatana.htm

What kind of wood would you use to build the platform that this sofa
sort of "sits" on?
I've seen this sofa close-up and there is an angle iron that runs the
length of the sofa underneath, to add extra support to keep the wood
from bowing. Please add your thoughts about what kind of wood. Also,
if you reccomend a certain type of wood, can you tell me where I might
find it and how much I should expect it to cost?

Also, I know I can slide a square piece of plywood inside of a couch
cushion, and then screw the cushion to the frame of the sofa, but what
about the backrest? How would I make a sturdy support for a backrest
cushion? I just can't picture this aspect of it in my head. Would I
just use something like an "L" bracket to give support? That would be
fine, but that's not what was done on the model I am trying to copy.
Thoughs again, please?

I highly respect you guys (and girls) and appreciate any advice I get
on this. Thank you for your time and I hope the rest of your day or
evening goes pleasantly.

Keith

That's a pretty long span. I'm thinking maybe a torsion box might do
the trick for that. For the backrest I believe you could just bolt one
some large L-brackets, or you could do some doweled M&T into solid
timbers within the torsion box.

JP

For the base - I would make a torsion box w/ the ribs going length wise w/
supporting cross members.

The rest of it - not sure yet - its just off the top of my head.


wrote in message
ups.com...
Hello, I want to make this style sofa on a really tight budget. Could
you help me answer some questions about the design of what is pictured
here? http://www.dellarobbiausa.com/produc...ofa/zatana.htm

What kind of wood would you use to build the platform that this sofa
sort of "sits" on?
I've seen this sofa close-up and there is an angle iron that runs the
length of the sofa underneath, to add extra support to keep the wood
from bowing. Please add your thoughts about what kind of wood. Also,
if you reccomend a certain type of wood, can you tell me where I might
find it and how much I should expect it to cost?

Also, I know I can slide a square piece of plywood inside of a couch
cushion, and then screw the cushion to the frame of the sofa, but what
about the backrest? How would I make a sturdy support for a backrest
cushion? I just can't picture this aspect of it in my head. Would I
just use something like an "L" bracket to give support? That would be
fine, but that's not what was done on the model I am trying to copy.
Thoughs again, please?

I highly respect you guys (and girls) and appreciate any advice I get
on this. Thank you for your time and I hope the rest of your day or
evening goes pleasantly.

Keith

Go to a used furniture store and buy a brand-name sofa in poor
condition. You're more interested in the structure than the finish.
The unit must be in good structural condition, because you can use the
frame as a basis for your creation. Sometimes charity resale stores or
Salvation Army resale centers will have something that is out of style
but structurally sound.

On 5 Oct 2005 16:59:41 -0700, wrote:

Hello, I want to make this style sofa on a really tight budget. Could
you help me answer some questions about the design of what is pictured
here? http://www.dellarobbiausa.com/produc...ofa/zatana.htm

Thanks for your responses guys.

So, to make a torsion box, I buy 2 sheets of MDF, and build a grid on
the inside of one of them using MDF also, or does matter if it's MDF or
2x4 type wood? Then attach another piece of MDF on top of that?
Sounds easier than I know it is. Can this be done without owning
tools? I can probably get the guys at home depot to cut the wood for
me. I just moved into an apartment and don't have any of my tools yet.


Thanks a lot for you replies.

Good Day,
Keith

wrote:
Hello, I want to make this style sofa on a really tight budget. Could
you help me answer some questions about the design of what is pictured
here? http://www.dellarobbiausa.com/produc...ofa/zatana.htm

That's some nice looking stuff!!!
______________

What kind of wood would you use to build the platform that this sofa
sort of "sits" on?

Seems to me that plywood and laminate is tailor made for it.
_________________

I've seen this sofa close-up and there is an angle iron that runs the
length of the sofa underneath, to add extra support to keep the wood
from bowing. Please add your thoughts about what kind of wood.
Also, if you reccomend a certain type of wood, can you tell me where
I might find it and how much I should expect it to cost?

Where did you see it? In the US?

Just about any 3/4" ply with a smooth surface (for laminate) should be
fine. Even particle board if it has additional cross supports. Build
up the edge thickness with narrower ply strips.

You can get ply at Home Depot and the like but they may not have
anything other than fir which may or may not be suitable. A better
place is a lumber yard, still better a cabinet maker supply place.
Around here, 3/4" virola is around $30 per 4'x8' sheet. Virola is a
wood from South America, looks like and has the same characteristics as
luan.
___________________

Also, I know I can slide a square piece of plywood inside of a couch
cushion, and then screw the cushion to the frame of the sofa, but what
about the backrest?

Why would you want to do that? Your example looks like it has a box
frame and (probably) zigger wire springs covered with padding and
upholstery material. That is, the cushions are tight (integral) rather
than loose.
_______________________

How would I make a sturdy support for a backrest
cushion? I just can't picture this aspect of it in my head. Would I
just use something like an "L" bracket to give support? That would be
fine, but that's not what was done on the model I am trying to copy.
Thoughs again, please?

The backs (and arms) of your example look like they have been made the
same as the bottom; i.e., a frame covered with padding then upholstered.
Back may or may not have zigger wire springs (probably not) but most
likely includes foam as well as dacron pad.

Most likely, all pieces (bottom, top and arm frames) were assembled
before covering. To do that, you'd need fair upholstery skills.

An alternative way (and possibly easier) would be to build and upholster
the bottom. Build the arms and a back all the same height, thickness
and shape and apply padding and muslin cover. Now, cut the upholstery
material long enough the wrap each completely and attach it to just the
*inside* of each piece. Attach each piece to the bottom and each other
with screws then finish attaching the upholstery material to the outside
of each. This would give you a "tuxedo" style sofa and you'd need loose
back cushions. Those woulld be easiest by going to an upholstery shop
and letting them make them up from wedge shaped foam. If this appeals
to you, you'd have to make the bottom piece of a width to give
comfortable seating after allowing for the thickness of the attached
back and wedges.

An easier way to upholster the above is to completely upholster the
insides of arms and backs, carrying that just an inch or so over the
tops and ends. Then attach them to the bottom frame. Next, upholster
the outside faces also carrying that an inch or so over the tops and
ends. You now have unupholstered tops and ends that need to be
covered...an attractive piece of hardwood would work well. The
advantage of this is that there is no sewing necessary.

Your biggest problem is going to be in the frame of the upholstered
bottom. The force from sitting on the couch and from zigger springs
wants to pull the front and back of the frame toward each other. Easy
answer is to cross brace the frame with wood but then you bottom out on
them when you sit...not a good solution. What you need - in addition to
stout lumber - are trusses. Commercially, they use steel ones...sort of
"U" shaped, tops of the "U"s attach near the top of the front and back
frame members. One could do something similar with wood knees attached
near tops and to stout wood cross pieces attached low enough so you
don't bottom out on them.

Now, if you build several smaller bottom frames - as it appears they
have done in your example - rather than one big one, you wouldn't need
the cross pieces but you would bottom out on the frame if you sat over
it. No big deal, move your butt

In all cases, use good stout hardwood that holds fasteners well. I'd
probably use 5/4 white oak (got lots on hand) but you could use thinner
if corner blocked.

--
dadiOH
____________________________

dadiOH's dandies v3.06...
....a help file of info about MP3s, recording from
LP/cassette and tips & tricks on this and that.
Get it at http://mysite.verizon.net/xico

I really don't think you can tackle this project without tools. The
guys at home depot will not do precision cuts, only "rough"
cuts and they will be very rough. Not to mention, they will probably be
in a bad mood if you ask them to do the number of
cuts a torsion box requries.

I think you are going to have to buy some tools to get this project
done. If the entire motivation for this project is to get a cheap
couch, I think you'd be much better off looking for a used couch. You
can get a decent used couch for under $100. The materials for this
project will probably end up being more than $100.

If the motivation to do this project is to have fun building stuff,
you'll need to buy some tools.

wrote:
Thanks for your responses guys.

So, to make a torsion box, I buy 2 sheets of MDF, and build a grid on
the inside of one of them using MDF also, or does matter if it's MDF
or 2x4 type wood? Then attach another piece of MDF on top of that?
Sounds easier than I know it is. Can this be done without owning
tools? I can probably get the guys at home depot to cut the wood for
me. I just moved into an apartment and don't have any of my tools
yet.

You are going to need tools.



--
dadiOH
____________________________

dadiOH's dandies v3.06...
....a help file of info about MP3s, recording from
LP/cassette and tips & tricks on this and that.
Get it at http://mysite.verizon.net/xico

Great reply except this guy wants to rely on home depot to make all the
cuts for him. Its a pretty ambitious project for somone w/o tools,
experience, a shop, etc.

To the OP. Here is an idea - if you can make the base frame. Then just
get a sutible looking couch and modify it to fit (Cut the legs off). If
you persue this approach then I would get the couch first and work from
there. Plywood, not MDF or particle board and steel angle brackets as
in the original. Laminate.

OK, to do it that way. You will need. (At a bare minimum!)
Circular saw
straight edge
drill
roller for contact cement
trim sized router
hand saw
hammer
glue
and probably more that I didn't think of in the 30 seconds I spent
thinking about this project.

No wrote:
Great reply except this guy wants to rely on home depot to make all
the cuts for him. Its a pretty ambitious project for somone w/o tools,
experience, a shop, etc.

Indeed. Didn't see his post about lack of tools til after I wrote it.
No loss, got me thinking about it and I might do it myself. For me, not
him

--
dadiOH
____________________________

dadiOH's dandies v3.06...
....a help file of info about MP3s, recording from
LP/cassette and tips & tricks on this and that.
Get it at http://mysite.verizon.net/xico

Its pretty trendy looking. I'm not sure I like the look at all.
Probably in a few years I would hate it. I guess I'm more of a function
over form kind of guy. Have fun.

My motivation is to have a custom made piece of furniture that works
with the size, shape and atmosphere of my apartment. The limitation is
that I have very little money (maybe $150) to put into the project.

I can purchase some tools, and I can bring the bare necessities from
home: drill, hammer, etc. I just don't have them right now because I
just moved here to chicago.

So, don't write me off as a hack for suggesting I might be able to do
it without tools, i'm just examining possibilities.

I suppose my question now is, what tools are downright necessary that I
should go out and buy right now? Thanks for everyone's help so far and
especially thank you very much to dadiOH for such a thoughtful and
detailed reply to my original question. I'm still doing this project,
despite any limitations. It will be done, in someway. Please keep the
advice coming if you have any more to give to me.

Thanks,
Keith

bf wrote:
I really don't think you can tackle this project without tools. The
guys at home depot will not do precision cuts, only "rough"
cuts and they will be very rough. Not to mention, they will probably be
in a bad mood if you ask them to do the number of
cuts a torsion box requries.

I think you are going to have to buy some tools to get this project
done. If the entire motivation for this project is to get a cheap
couch, I think you'd be much better off looking for a used couch. You
can get a decent used couch for under $100. The materials for this
project will probably end up being more than $100.

If the motivation to do this project is to have fun building stuff,
you'll need to buy some tools.

wrote:
My motivation is to have a custom made piece of furniture that works
with the size, shape and atmosphere of my apartment. The limitation
is that I have very little money (maybe $150) to put into the project.

I can purchase some tools, and I can bring the bare necessities from
home: drill, hammer, etc. I just don't have them right now because I
just moved here to chicago.

So, don't write me off as a hack for suggesting I might be able to do
it without tools, i'm just examining possibilities.

I suppose my question now is, what tools are downright necessary that
I should go out and buy right now? Thanks for everyone's help so far
and especially thank you very much to dadiOH for such a thoughtful and
detailed reply to my original question. I'm still doing this project,
despite any limitations. It will be done, in someway. Please keep
the advice coming if you have any more to give to me.

Best advice I can give you now is to give it up...no way no how are you
going to be able to do what you want for $150. Have you tried pricing
upholstery material? Foam?

Your cheapest course would probably be what someone suggested...build
the platform, buy a second hand couch, whack the legs off and set it on
the platform. Forget laminate for the platform too ($50+ per sheet) and
go with flat paint.

--
dadiOH
____________________________

dadiOH's dandies v3.06...
....a help file of info about MP3s, recording from
LP/cassette and tips & tricks on this and that.
Get it at http://mysite.verizon.net/xico

dadiOH wrote:

Best advice I can give you now is to give it up...no way no how are
you going to be able to do what you want for $150. Have you tried
pricing upholstery material? Foam?

I'm not trying to be negative or discouraging but you need to be
realistic money-wise.

When I was in college I did something similar for an apartment...built a
sofa and two arm chairs, both with cheap goods. Bought an unfinished
desk, chair and bookcase...used bed, fridge and kitchen table w/chairs,
new rotisserie oven...couple of sling chairs, 4-5 dime store lamps and a
couple of rugs. Cheap drapes from Sears. Cheap stuff and sweat, you
get the idea...

I don't remember what the cost was but when I left I sold the lot for
$400 and it cost me more than that. Those are 400 1958 dollars...now it
would be $2,500 minimum. I really don't think your $150 budget is
realistic.

--
dadiOH
____________________________

dadiOH's dandies v3.06...
....a help file of info about MP3s, recording from
LP/cassette and tips & tricks on this and that.
Get it at http://mysite.verizon.net/xico

I feel perhaps that you are mis-taking me. I do not wish to create the
exact replica of the sofa in the picture, I want to make something that
functions as such. When I said $150, I was basically thinking just of
the wood and tools and hardware to put together the frame. Once the
frame is built, I would throw old couch cushions on top and use it as a
bench until I get the money and materials to finish it the right way.
I guess my first goal is to really just have a bench that goes around
the corner of my apt. It could even act as a stylish asian coffee
table if that's all it ends up being.

I like the idea of simply building the frame and slapping a couch down
on top of it, and if I come across a used sofa that lends itself well
to that, I will do that. However, I wanted something simpler and
cleaner looking than a full blown sofa, but still something comfortable
to relax on. It's tricky.

Again, thanks for all the help i've received, and hopefully a few of
you will stick it out with me until I figure out exactly how i'm going
to do this.

Good day,
Keith

Make sure you read to my last comment for the most important thing
about this project.

OK - here is what you could do. Just make a platform for cushions. Make
it L shaped to sit in a corner. if you can fasten it to the wall you
will have that much more support and could do w/o learning about
torsion boxes.

Assuming an L shape

You will need:
Materials
two sheets of 3/5x4x8 plywood or MDF - 2x$45 = $90 (Good stuff, A/B or
a hardwood veneer if possible, you will paint it)
2x4s - qty 6 @ $2.69 = $16.14 Use these to form up the frame that the
plywood will attach to.
Screws - One box of 1 5/8" multi purpose screws (Drywall screws) and
one box of 3" deck screws to hold the frame together. about $6
sandpaper $3
paint = $20
glue = $4
Cushions = Who knows, I suspect you could end up spending a lot here
Materials, without cushions = $139

Tools:
Saw to cut the plywood (Borrow one from a neighbor) = Free
Drill/driver = (Again Borrow one) = Free

OK, so even if you spent nothing on tools I cant really imagine
building a decent base for under $150. A crude base is possible at that
price. There could be some techniques for making this not too bad with
the above materials but would require more skills and tools.

Post here if you want some suggestions for making the base sort of
niceish with the above materials.

Here is a suggestion - try and make just a coffee table in the style if
you posted picture without any cushions. If you can do a decent job of
that then move on from there. If you are dead set on a couch then I
would suggest starting with the cushions. Price them out. If you find
the right cushions then you can design your platform around them.

Oh - And one more thing. Once you get established, have more money,
find a wife and move to the burbs. THERE IS NO WAY IN HELL YOU WIFE
WILL LET YOU MOVE THAT THING INTO YOUR HOUSE.

FYI, I have a coffee table I built in college. Modeled after the tables
at chili's restaurants. Tile top, etc. It came into the house for a
short time but was banished pretty quickly.

Thank you very much for your reply. This is the sort of post I needed.
You mentioned that you could give me more suggestions on making a good
"quality" base with my limitations? If you have a moment, I will
definitely read your suggestions and see if I can do it.

Good night
Keith

Here is what I was thinking....

You will make a frame out of 2x4s, you have two options to make it look
better than just slapping it toghether....

Option 1
A standard 2x4 is sanded on all 4 sides. This creates rounded edges. If
your 2x4 is visible, you will have a gap where it meets the edge of the
plywood. Find somone with a long bed jointer or a planer who can trim
the 2x4s to make them perfectly flat or square. Once attached, it will
look better, because it will fit tighter and have no gap at the edge of
the 2x4 and the plywood. You still have the issue of the ugly edge of
plywood which will still be visible after painting.

Option 2.
make your 2x4 frame, do not worry about planing or jointing the 2x4s
unless its easy to have this done and doesn't cost you anything. you
will then wrap your 2x4 edge with the plywood. This would require you
to cut a very accurate 45deg edge on the surface plywood and on the
front plywood edge. Attache these with glue and screws to the 2x4
frame. Upside of this aproach - it will look the best. Downside of this
- It will be very dificult to do if you do not have a perfectly
straight frame and acurate cuts on the plywood.

Good luck