I cannot offer advice without photos of the space. Please share photos and floorplans

Benchmade Modern does fabulous custom sofas and sectionals that can be configured in many dimensions - overall length, seat depth, length of chaise. They also have a ton of fabric choices and can typically deliver in 2 to 4 weeks. I don't work there (haha), but I'm getting ready to order all my sofas, beds and counter stools from them. They aren't cheap, but after spending months looking at "almost right" alternatives, or waiting 3 to 5 months for Ethan Allen to deliver, I decided to go with Benchmade.

Lots of companies will allow you to build your custom sectional. All you had to do is Google Custom Size Sectionals.

https://www.livingspaces.com/departments/custom-upholstery/sectional-builder

Century Furniture. We had a sectional custom made by them 11 years ago in our previous house.

Thank you everyone! I am looking for a custom sectional that is highly recommended for comfort and wear and tear. Family of 5 and 2 100# dogs. I would have our current sectional recovered, but my husband doesn't like the way it sits (he never has) so want to go in a different direction. Given it is hard to go and sit on a sofa that has to be custom made, I'm hoping to find someone with real experience in comfort, etc. of whichever custom brands are out there. Thanks so much for all your help so far!

Adding I have looked into some custom sectional builders - the components do not add up to the right measurements for our room so this would truly need to be custom fit.

Why don't you just have the current sectional repaired (tighten the wood joints, refinished, etc.) and reupholstered (including replacing all the foam inserts and cushioning)? We've done that twice with our current couch because it's a unique shape and fits the space perfectly. You just need to find a quality/highly competent upholsterer. It's expensive, but worth it if you love the piece.

I would love to just have it repaired and recovered but the actual seat size and dimensions are uncomfortable for my husband and that can't be fixed.

Obviously the one you had was not perfect only in size . Wahy not think about a different idea for seating. IMO sectionals are awful for actual seating comfort.

Hi All - to be clear, current sectional fit the dimensions of the room perfectly. It fit wall to wall across the back of the room almost like a sunken sectional. It did not suit my husband as far as depth of seat. I am looking for a new sectional that would fit the room wall to wall as well, but with deeper seats. Due to the size and purpose of the room we prefer a sectional. Thanks!

Have you measured a specific depth and height that would be comfortable for your husband? It seems like Century and Benchmade do not customize depth. You really are only customizing the length of your sofa in 5" increments. However, if they have a depth that is already what your husband finds comfortable then it might be a good place to shop.

Also, do you have thick fluffy removable back pillows on your current sofa? If so, you could have it reupholstered as a tight back and gain extra inches in depth. I did this with a vintage Baker sofa from the 80s. It is now deeper and sturdy as a tank.

Cococo Home makes some custom and modular sectionals - we have 2 sofas from them and have been very happy