From design to delivery, our made to order sofas are crafted with skill and care using age-old techniques to produce premium pieces of furniture that will enhance your home for years to come. Discover how the Dalvik sofa is made in this week's Style Note.
The Sofa
Great sofas start with a great design and our Dalvik is inspired by traditional Chesterfield sofas with a deep buttoned back and luxurious rolled arms. Great attention is paid to ensuring the proportions and silhouette of each sofa is perfect in terms of both comfort and style. The Dalvik is made exclusively for Cox and Cox by our family owned workshop at Long Eaton in the East Midlands. To this day, Long Eaton is recognised world-wide as the centre of excellence when it comes to upholstered furniture.
The Frame Maker
Once your order has been placed, the Frame Maker will consult the cutting list for details of all the pieces needed for the sofa frame. Then the standard rails will be cut by machine to the correct lengths and widths for the Dalvik, ready to be hand assembled, with glue, dowels, screws and leg fixings.
The Pattern Cutter
A roll of your chosen fabric will be given to the Pattern Cutter alongside details of your order and the sofa specifications. The material will be carefully checked for faults and then hand cut to size using patterns and measurements. At this stage, the inside back and arms will also be marked for button holes.
The Machinist
Once the pieces are cut, the sofa covers are sent to the sewing Machinist and stitched according to the design specifications. The cushions are passed to the cushion department to be hand filled with the correct interior material while the sofa covers are sent to the upholsterer.
The Upholsterer
From here, one dedicated Upholsterer will make the complete sofa from bare frame to completion, using staples, canvas, upholstery webbing, clips, springs and felt to prepare the frame for the foam support.
The buttons, which are so integral to the appeal of the Dalvik, are hand made using a manual button machine and the arms and back covers are upholstered with the buttons using a bayonet needle and twine, which is tied off behind the springs.
The Delivery
Next the seat spring is attached and covered with canvas and foam, then the seat cover added, followed by the outer arms and outer back. At long last the cushions are reunited with the sofa and the legs are attached, ready for inspection. Once approved the Dalvik is carefully packed and delivered to your home, where it will be enjoyed for years to come.