Inspired By HGTV’s Design Star: Rug-Covered Ottoman

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Recently on HGTV’s Design Star, contestants (brilliantly) crafted an ottoman using a flat-weave rug. Want to recreate this drool-worthy furniture project right at home? Now you can.

Have you been following this season’s Design Star on HGTV? I’m totally addicted.

One of the highlights this season has been contestant Casey Noble’s idea to turn a rug into an ottoman in the episode Dining Room Challenge (see Casey in the image above). I loved how this piece turned out; a perfect example of clever repurposing of existing household items. I’ve even seen a couple furniture companies selling ottomans upholstered with vintage rugs.

Inspired by Casey’s rug-turned-ottoman, I looked into how to DIY it.

A flat-weave version, like the one Casey used, is the best option for a DIY rug ottoman because it behaves like a thick upholstery fabric. (A fluffier rug would be difficult to wrap around the ottoman without bunching.) A round ottoman/stool like the one Casey made over is considered a boudoir stool. The seat is low and not heavily padded, making it an utterly doable DIY project — no excuses!

1. Strip the piece down to the frame. When you’re reupholstering a piece of furniture, this is always the first step. Remove all the tacks, nails, and staples — keeping the fabric and foam in place.

2. If the foam needs replacing, create a pattern for it. Drape a piece of craft paper over the frame and outline around the edge of the frame. Bring your template in to a local foam center to get a custom piece of foam for your ottoman. (In New York, I go to Economy Foam and Futon.)

3. Spray the top and sides of the foam with a spray adhesive. I recommend using 3M Foam Fast Adhesive. Wait five minutes for the glue to become tacky and then attach to the wood frame.

4. Make a rolled edge with the rug. In his Book of Upholstery, Matthew Haly explains how a rolled, or rounded, edge is typically found on upholstered stools. Spray the side of the foam with 3M Foam Fast Adhesive, being careful to spray only the top half of the side. Tuck the bottom edge of the foam using an upholstery regulator — a handheld tool resembling a giant needle, which is designed to make adjustments to furniture stuffing. With your other hand, pull the top edge of the foam over the bottom edge and press firmly into the frame. Continue this all the way around the ottoman.

4. Use a layer of Dacron over the foam. Experienced upholsterers use this trick to help prevent the foam from degrading. To attach the piece of Dacron, spray the foam all over with a fast tack upholstery spray adhesive. Wait two minutes until the adhesive is tacky, then drape your Dacron over the foam. Staple it to the ottoman using a staple gun, as seen by Design Star contestant Courtland Bascon in the image above. It’s best to position the first staple in the center front of the form, then center back, followed by the center points of the two sides.

5. Measure and cut your rug. Use a cloth tape measure to measure the diameter of the padded ottoman top. Add four inches to the diameter (so you have extra to wrap the rug under the ottoman) and cut a square with sides that are that length.

6. Drape your rug over the ottoman, and pin the edges of the foam in a few spots. Smooth your hand over the rug to make sure the tension is consistent; that’s the key to getting a smooth, polished look. Use upholstery tacks to pin the rug around the circumference of the ottoman frame. Carefully smooth down the rug as you work.

7. Stretch the rug around the form, and staple the rug to the underside of the form. Shoot the staples on an angle and keep them about 1/2″ apart. Remove the upholstery tacks as you staple around the ottoman. Trim any excess fabric once you’re done.

Via DIY Life

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