How to make a wooden storage ottoman with a cushioned top

Building a wooden storage ottoman with a cushioned top is a fun and rewarding project! Here’s a step-by-step guide to help you make one:

Materials:

1. Wood (plywood for the base and sides, solid wood for trim and legs)
2. Foam (for the cushion top, 2-3 inches thick)
3. Fabric (for upholstering the top)
4. Batting (for extra padding under the fabric)
5. Wood screws (for assembly)
6. Wood glue (optional, for extra strength)
7. Hinges (for the lid)
8. Staple gun and staples
9. Wood finish (stain or paint, as desired)
10. Sandpaper (to smooth the wood surfaces)
11. Saw (if you need to cut the wood)
12. Drill (for pilot holes)

Tools:

• Hammer or screwdriver
• Measuring tape
• Scissors (for cutting fabric)
• Fabric glue or spray adhesive (optional, for attaching foam to the lid)

Step-by-Step Instructions:

1. Build the Box:

• Cut the wood: Start by cutting your plywood for the sides and base. You’ll need four pieces for the sides, and one piece for the bottom. A common size for an ottoman is around 18” x 18” x 16” (height x width x depth), but you can customize this based on your needs.
• Assemble the sides: Attach the sides to the base with wood screws and wood glue (optional for extra strength). Pre-drill pilot holes to avoid splitting the wood.
• Add the trim (optional): If you want a more polished look, you can add trim to the edges using solid wood pieces, cutting them to fit and nailing or gluing them to the box.

2. Prepare the Lid:

• Cut the lid: Cut a piece of plywood for the top that matches the dimensions of the box. This will be the base for your cushion.
• Attach hinges: Attach the hinges to the back of the lid and the back of the box. Make sure the hinges are positioned well enough so the lid can open and close easily.

3. Cushion the Lid:

• Cut the foam: Measure and cut your foam to fit the lid. You can use a serrated knife or an electric carving knife for a clean cut.
• Attach the foam to the lid: Use spray adhesive or fabric glue to attach the foam to the top of the lid. Be sure to center it and press it down to avoid air bubbles or wrinkles.
• Add batting (optional): If you want extra softness, wrap the foam in a layer of batting before applying the fabric.

4. Upholster the Lid:

• Cut the fabric: Cut your fabric large enough to cover the foam and the edges of the lid (you should have at least 2-3 inches of fabric around the edges).
• Staple the fabric: Lay the fabric over the foam and pull it tight. Start stapling the fabric to the underside of the lid, pulling it taut as you go. Staple along all four sides, making sure the fabric is smooth and wrinkle-free.
• Trim the excess fabric: Once all sides are stapled, trim off any excess fabric.

5. Finish the Box:

• Sand the edges: Sand all of the exposed wood to smooth out any rough edges or splinters.
• Finish the wood: You can stain or paint the box and trim as desired. Apply a clear wood finish if you want to protect the surface.

6. Attach the Lid:

• Once everything is dry and finished, attach the lid using the hinges. Make sure it opens and closes easily.

7. Add Feet (optional):

• If you want legs or feet, you can add small wooden blocks or pre-made furniture legs to the bottom corners of the ottoman for a lifted look.

Final Tips:

• Make sure your hinges are heavy-duty enough to support the weight of the lid and cushion.
• For a more elegant look, you can add decorative nailhead trim along the edges of the fabric.
• Always test fit your foam and fabric before stapling to make sure everything looks aligned.

How’s that sound? Ready to get started or have any more questions on details?