Chaise Lounge; purpose, concept, design and construction

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Blog entry by sgtsprout posted 06-30-2012 08:43 PM 3521 reads 0 times favorited 0 comments Add to Favorites Watch

So this all started with a request from the wife several years ago when she bought an E reader. She wanted an area in the bedroom that she could read and relax for hours at a time. So the purpose was of course for her to enjoy her books comfortably.

The concept came from traditional chaise lounge chairs but we are antes something more comfortable and conforming to the body that would allow one to lay for hours. We scouring do the Internet and really didn’t find anything she wanted. So I layer out some simple design drawings similar to the final construction pictures below.

Fast forward 2 years and I caught my wife reading again at night next to me at night when I was trying to get some shuteye. As usual I complained as I like as much darkness as possible. So maybe a little selfishness but that invoked a drive to the big box stores to start construction. Prior to that I laid out my designs and brought them with me for some additional inspiration. So between the wife and myself we figured a way to make it relatively inexpensive using standard construction supplies. Initial material purchased was 2 – 4’ x 8’ 5/8” plywood $20 each (only used 1), 6 – 2” x 4” x 8’ $2.70 each($16), 12 – 1” x 1” x 8’ $1.50 each ($18), had all screws but estimate that would of cost about $25, (needed a new 12” saw blade for my compound miter saw a $50, but will be used for many more projects to come. My cost so to date for what was used is about $54 (+ $25 for fasteners already had, would be about $80).

So construction started with laying out the curves on the plywood. Once we found something we liked, I cut it using my jig saw. I laid the first piece on the same piece of plywood so I washable to get 2 curved surfaces from 1 plywood purchase (wife’s idea). Then we laid them together clamped and used the first piece as my template. Now remember I am not concerned with precision as my design consists of fabricing the entire furniture project. But I did still sand down all surfaces to easier work with the pieces during construction and fabricing.

Now both sides are cut and now to lay out the box frame. I basically constructed 2 walls no higher than the shortest. Height of the sides which is about 20”. Once both walls were constructed using nails I boxed them out using the same 2” x 4” framing ensuring they were all equally cut 18” and squared when attaching using large screws. At this point I have a frame 20” x 5’ and 2 curved surfaces

Now I attach the surfaces to my box frame. (if I were thinking I would have only attached 1, so as to help with a future step). But I am like a box of rocks and seeing the light at the end of the tunnel and start rushing just a tad. So now I have this beautiful looking chaise form.

You may also see 2 different curved surfaces. Before we attache the surfaces we realize we want a slightly different profile, so I cut them one final time and you will see those differences in some pictures. Now I cut my chaise top 1” x 1” x 18” braces. Once I cut all of them (30 mind later) I can lay out the top, sort of. It is at this point I realize shoot. They may not be strong enough I need some reinforcement. Meaning I need something underneath the 1” x 1”’s. Something to ensure the screws hold. So that is when I think I don’t something to overbearing but something that matches the profile and support the underside of the top where one will lay on. Luckily I don’t attach all my top pieces. I have some room to get cardboard and create templates for each side. This was time consuming getting and exact profile match as you might be able to imagine. Maybe there is an easier way. Hmm such as leaving one curved surface unattached or some other method. I think too late just get on with it. So using the cardboard templates and several cuts with the bandsaw I attach 5/8” plywood reinforcement on the inside of the curved surfaces.

I finish attaching all 1” x 1” top pieces and bam, we have what looks like an uncomfortable chair.

But wait, my next blog will hopefully correct that. Of course part of the original design is to make this a comfortable relaxing area. To come, fabric and ambience.

-- "There are no gains without pains." -Benjamin Franklin

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