DIY Round Ottoman: How to Make a Round Ottoman

Item # X-HT-300514

Are you looking for a comfy place to rest your feet, one that can be modified for indoor or outdoor use? Check out our comprehensive tutorial on how to make a round ottoman! We will walk you through every step of the creation process from start to finish, so you’ll be left with a stylish and functional addition to your living space. Let’s get started.

Learn how to make your own round ottoman with our help.

Most ottomans are constructed from a wooden frame with foam on top, but our ottoman consists of layers of foam glued together. This difference makes it a very easy, beginner-friendly project. Our round ottoman also features gorgeous channeling in the top panel, a top stitch and a U shaped zipper in the bottom panel.

To construct the large block of foam needed for your ottoman, you simply need to cut and layer foam pieces on top of each other. Our round ottoman is 12 inches high and has a diameter of 19 inches. We’ve chosen to use High Density Polyurethane Antimicrobial Foam (Firm) because of its long lifespan and its ability to resist mold and mildew. And because our ottoman will be used on a boat, we chose Sunbrella® Horizon Textil Charcoal 54" Vinyl Fabric for the exterior. This waterproof vinyl offers incredible stain, fade, moisture and mold resistance. If you’re using your ottoman outdoors, or anywhere that could come into contact with a lot of moisture or spills, we would recommend a vinyl fabric. However, if you only plan to use your ottoman indoors, you could use a high-quality upholstery fabric.

Need help choosing the right foam or fabric for your project? Reach out to us! We’re available via email at, by phone or through the chat function on our website. Our customer support staff would be more than happy to assist you.

Video Chapters:

  • Cutting & Gluing Foam Layers – 0:50 min
  • Cutting Fabric to Size – 8:12 min
  • Sewing Channeling in Top – 14:04 min
  • Sewing “U” Shaped Zipper in Bottom – 19:34 min
  • Joining Boxing to Top Plate – 29:45 min
  • Sewing a Top Stitch – 36:41 min
  • Joining Assembly to Bottom Plate – 40:13 min
  • Inserting Foam in Cover – 44:26 min
  • Materials & Tools List - 50:19 min

Materials List:

  • High Density Polyurethane Antimicrobial Foam (Firm) 6" x 24" x 80" - (#286F2480)
  • Sunbrella® Horizon Textil Charcoal 54" Vinyl Fabric - (#10201-0004)
  • Cushion Underlining Fabric from Sailrite (for bottom side, if using a woven fabric)
  • Foam Lock Spray Adhesive 12 oz. - (#120464)
  • Fabric Backed 1/4" Sew Foam 58" (5Yds) - (#121506)
  • V‑92 White UV Bonded Polyester Thread 4 oz. - (#100079)
  • YKK® Continuous Zipper Chain #4.5 White (Coil Chain) - (#104385)
  • Seamstick 1/4" Basting Tape for Canvas & Upholstery (36Yds) - (#122065)
  • YKK® Zipper Slider #4.5 White Metal Single Non‑Locking Pull (Coil Chain) - (#104335)
  • Cushion Wrap Silk Film 54" (10Yds) - (#103933)

Tools List:

  • Sailrite® Blade Foam Saw V2 with Carrying Case (110V) - (#121244)
  • Clear Acrylic Ruler 6" x 24" - (#102400)
  • Comfort Grip Rotary Cutter 60mm - (#9655)
  • Self Healing Rotary Cutting Mat 24" x 36" - (#120257)
  • Gingher® Scissors Right Hand Lightweight 8" - (#101017)
  • Triangle Tailor's Chalk ‑ White - (#121912) (if sewing in channeling)
  • Sailrite® Ultrafeed® LSZ‑1 PLUS Walking Foot Sewing Machine (110V) - (#300602)
  • Sailrite® Ultrafeed® Industrial Sewing Table & Workhorse® Servo Motor (110V) - (#120931)
  • Scribe‑All® Black Marking Pencil for Vinyl - (#121977)
  • Thread Clipper Kuroha - (#121908)
  • Seam Ripper Deluxe - (#18104)
  • Deluxe 5 1/2" Magnetic Sewing Guide - (#103597)
  • Shop Vac, Yardstick