Ordering a custom sofa is different from buying off a showroom floor. Here's exactly what happens from the moment you place your order to the day it arrives at your door.
Week 1: Order Confirmation and Materials
Once your order is placed, we confirm all specifications: dimensions, fabric selection, leg finish, cushion fill. We then order your specific fabric from the mill. Some fabrics ship within days; specialty materials can take 2-3 weeks.
Weeks 2-4: Frame Construction
Your frame is built by hand in our Hickory workshop. Kiln-dried hardwood is cut, joined, and reinforced at stress points. Corner blocks are glued and screwed—not stapled. The frame is the skeleton of your sofa; we don't rush it.
Weeks 3-5: Spring System and Foundation
Depending on your configuration, we install either eight-way hand-tied springs or a sinuous spring system. Webbing is stretched and secured. The foundation layer of padding goes down.
Weeks 5-6: Upholstery
This is where the magic happens. Your fabric is carefully cut to minimize waste while ensuring pattern alignment. An experienced upholsterer—most of ours have 15+ years of experience—stretches, tacks, and finishes every surface. Cushions are filled and fitted.
Week 7: Quality Check and Shipping
Every piece is inspected before leaving our workshop. We check seams, cushion fit, leg alignment, and overall finish. Then we arrange white-glove delivery to your door.
Why 50 Days?
We could work faster. Some manufacturers promise 2-3 weeks. But speed requires shortcuts: pneumatic staples instead of hand-tied joints, assembly-line upholstery instead of single-craftsman attention.
Our 50-day lead time is honest about what quality takes. We'd rather set realistic expectations than deliver something we're not proud of.
Tracking Your Order
You'll receive updates at key milestones: fabric received, frame complete, upholstery started, ready to ship. If you have questions at any point, we're a phone call away.
