I have been seeing some good progress in my upcycle project to repurpose my rock climbing crash pad into a couch. So far, I have fully fleshed out the design, planned on my materials, and now just need to fabricate the frame.
In order to minimize cost and materials, I spent some time working out how I could get all of the pieces to be cut from one 4’ x 8’ sheet of plywood. I scaled all the pieces and drew out a way for all the cuts to be done so that this would be possible. This will make the fabrication process very straightforward and simple, and ensures that I will be ready to make all of the cuts correctly now (measure twice, cut once!).
I plan on cutting all of my frame pieces from a single sheet of plywood similar to the one above. I am planning on the thickness of all of the frame pieces to be 0.5”. I will be discussing the best way to make the cuts with Idea Forge staff tomorrow. Since I work there, I am hoping to utilize the makerspace tools to fabricate my couch frame. I went to Resource Central in Boulder last week to consider the option of renting tools and buying scrap material, but I think it makes the most sense to utilize the Idea Forge since I have access to it right now, and to probably just buy a single sheet of plywood to ensure the quality and uniformity of the wood. I will likely be cutting the frame sometime next week.
Now that everything is designed, really the last step is just to cut the frame pieces. Since the design doesn’t require any fasteners, it should all fit together like puzzle pieces. And, the crash pad should be able to just sit on top of the frame without any extra fastening too; although the straps that go from corner to corner that can be seen in the photo above should help it keep the shape needed when adjusted correctly to prevent the pad from slipping off of the frame. If a lot of slipping does occur, I may end up adding an upturned piece of wood to the seat part of the frame to hold the pad in place.
I have also collected stickers for decorating the frame with climbing brand logos after I have put it together. A commenter on my last post made a good point that while the stickers add to the climbing aesthetic; I should be careful with my placement of decoration/stickers in order to preserve the sleek minimalist/modern look of the couch frame. I will be keeping this in mind when making the final touches on the couch.