How to make a "Gantt Jewel Box Ottoman.


Project Report #5.  Harrisburg Symphony Decorator Show House

This week's fabrication for the Library was spent mainly on making 4 "Jewel Box" ottomans, one for each set of book shelves.

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A design sketch and materials estimate was completed.

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Hard wood pieces were curt, pre drilled and assembled with wood glue and drywall screws.

Here the frame is complete and outside finish panels have been cut from 1/4" ply board.

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A dark color cotton duck is stretched over the frame.  Fabric strips in 2 shades of blue are cut 3" wide to be pressed and turned to create 1" finish strips.

Before the weaving begins three layers of fiber bat are cut to the shape of the cutouts in the 1/4" ply board finish panels.  These are attached to the green duck covering to line up with the opening in the finish panels.  This will assure that the woven part will be padded only where it shows and not add extra thickness behind the finish panel.

To weave the strips first stretch and staple all the horizontal strips.  But the edges together.  After they are all attached weave the vertical strips and staple.

When the weaving is complete it is time to stretch and staple the webbing on the top.  Again so as not to add bulk where the finish panels will be attached., the webbing is stapled to the top of the frame not on the sides.

A piece of 2 1/2 to 3' medium density foam is cut 1" larger than the dimentions of the frame top.  Spot staple it through the sides to the frame top.

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A layer of furniture poly bat is large enough to cover the top an about half of the sides.

Center the top fabric.  Staple a side in the middle. Then staple the opposite side in the same place.  Repeat the process on the top and bottom.  When you are satisfied with the amount you are pulling the top fabric.  Begin stretching and stapling the top fabric much like stretching a  canvas.   Side to side and top to bottom.  Finishing at the corners.

I used foam adhesive to attach the velvet.  The results were not as good as I hoped.  Next time I will attach it with 1/4" staples.

Cut out the center of the space leaving about 2" around the sides.  Now cut relief cuts into all corners and at rounded parts.   Cut the fabric all the way into the wood.  Pull the fabric tight being especially careful to see that corners are tight and staple

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When all the panels are covered it is time to cover 3/8"  and 1/4"  cording.  The 3/8" is to be stapled to the frame to finish the top of the finish panels when they are attached.

The 1/4" cord is to trim the edges of the center design of the finish panels.

Begin on an inside corner.  Cut the cording back under the fabric about 1".  Attach the cord so that the fabric covers the corner but the actual cord inside is 1/4" in from the corner.  

This will allow space for the cord to fit when finishing. 

Position the cord so that the thickness of the cord is aligned with the edge  of the finish panel.  When you reach the beginning point cut the covered cord about 1" longer than ther stopping point.  Strip the cover back and cut the cord so that it will fit neatly into the 1/4" space saved for it.   Staple the fabric in place.

Use small finish nails to attach the finish panels to the outside.  A silk rosette and rhinestone ad the elegant final touch.