Victorian-inspired chaise lounge for DD (ongoing!)

This is also being actively posted to DoA, but I thought I'd share it here too since I'm doing this project for my DD! (And she's in some of the progress pics too)

I've had this 1/6 scale set of chaise lounge, footstool/ottoman, and armchair for years. I originally got them for my old Monster High and Pureneemo dolls way back, and they're actually jewelry boxes, so they open at a back hinge.

Ever since I got into BJD and Dollfie Dreams I've been more into larger dolls, so I can't use these anymore, but I love the style.
Thus, I've decided to recreate them in DD scale myself!

My first project will focus on the chaise lounge / sofa.

I won't be using the same fabric, but I'm going to try and make the shapes and construct as similar as possible, just in a much larger scale.

This meant I had to do a lot of math... Not hard math, just a lot of it.

I wanted to be really precise, so I took as many measurements as possible. Then all I had to do was convert all of these to 1/3 scale. I could have done the math by hand but I'm lazy so I used a converter tool online.

I also took careful note of how each of the pieces was put together, as well as I could see. I was actually really surprised at how some of the pieces came together, as I hadn't really looked closely at them before. It's basically almost all cardstock of various thickness, covered in fabric and layered. Only the seat and backrest puff seem to be actually stuffed with anything.

I didn't want to dedicate too much effort without knowing if the new measurements would work, especially since the lounge wasn't originally in perfect 1/6 scale and my 10% upscale was just me guessing. So I decided to make a mock-up of the important parts!

I used cardboard -- finally had a use for all those shipping boxes I saved!! -- and cut out and taped together the baseboard and seat section pieces, as well as a rectangle for where the arm of the chair would be. I was honestly really surprised at how stiff and sturdy it felt even just with these "cheap materials". It didn't even have as many layers as the final would!

 

The Stuff I Actually Worked on Today:

The proportions ended up being really odd, so I took some advice from the replies to my post on DoA and adjusted some things, namely checking my doll's seated measurements and making the seat narrower.
I measured her thighs first and used that as a guide to guess two possible death depths, which I marked on the original mock-up.

Then I sat her down on it while it was placed on a box for height. At a fully pushed back seating position, 16cm seat depth seemed to be the best choice.

Incidentally, the height of the mock-up on the box was actually perfect for her seating height too, so I measured the distance from the seat to the table, which was also 16cm. This would be the total seat height, which includes all the baseboards, the seat while stuffed, and the chair legs.
I checked the added up measurements I currently had, and those were only 14cm total. I'm planning to also bevel the edges of the insert foam but I'm not 100% sure it will go well.

The foam I have is 2.7cm thick and squishes down to approx 2cm. I'd consider it a "working height" of 2.3 to 2.5 cm then, since I don't think a doll will compress the foam as much as me squishing it at max strength with my fingers would.
I adjusted my measurements to accommodate the foam, so the seat's total height from the floor becomes 16.4cm, which allows for the cushion to potentially squish as far as 16cm.

Second Attempt At Mock-up (50%-ish progress)
Next I decided that I might as well make a full mock-up of everything since I was having so many issues with scale.

I worked on the backboard main piece for a while. It was difficult to adjust the measurements and then accurately draw the shape. It was originally too short, and then too tall. I think I might make it slightly shorter still, but that's as easy as just trimming the bottom! I'm also considering raising the arm height if I do trim the bottom.
Notably, I just cut the original seat base for this instead of making a new one, so I need to redo the curved end too.

I stuck the seat base to the backboard at the height where the top of the foam would be. It's missing all of the bottom section for now, which I will make later, plus legs. For now, I raised it on some random objects/scraps.

Materials Planning Notes
For the good copy materials, I'm able to buy two types of craft foam board: 1.5 cm thickness, and 0.5 cm thickness.
I forgot to account for this in the original measurements, but this means anything using foam board needs to be in a multiple of 0.5cm.
I'm considering using thick cardstock for some parts that are thinner than 0.5cm or that have less even numbers, but I don't know where to buy it.
Everything will be cut with a scroll saw (I think that's what it's called, anyways) so the edges won't be nearly as jagged and rough as my box-cutter cardboard mess is!

As for fabric, I actually have no clue what I'm gonna use yet. I was considering floral cottons, or maybe real upholstery fabric, but that might be too thick. I'm either going to use a pale floral like the original, or a solid tone fabric with a subtle pattern.

 

Things that need to be worked on next:

♡ Adjust backboard height, raise arm

♡ re-round out the protruding seat end

♡ create the 3D arm structure

♡ mock-up the seat volume and legs (+ find jewellery box legs or make some?)

♡  find fabric to use for good copy

Edited February 6 by meltychoco_BJD

This is so in-depth and cool! I made a couch outta cardboard, but it turned out kind of funky, so I'm absolutely taking notes from your techniques!

5 hours ago, PlasticJester said:

This is so in-depth and cool! I made a couch outta cardboard, but it turned out kind of funky, so I'm absolutely taking notes from your techniques!

I'm glad my process can be helpful to you! Honestly, without seeing other people's construction methods + observing the existing 1/6 couch, I'd have no clue where to start lol. It's always great to have examples to work from!