Published at Friday, November 02nd 2018. by Lakisha Hopkins in Sectional Sofa.
I want to show you how to make a plywood sofa sectional, be sure to check out all the plywood projects on our playlist, so we designed this sofa for our deck. A couple things we considered when designing it was we wanted an l-shaped sofa and a place to store our cushions during the storm to keep them drier. Each section of the sofa will be made out of two sheets of 3/4 inch birch plywood. To start off. I use my circular saw to cut out the main pieces so that they're easier to manage for the final cuts on the table saw first, let's build the base frame of the plywood sofa sectional first cut the plywood to length and width then mark out where you cut out the notch for a support beam with a jigsaw, the notch will be on the top center of the sides.
After the notches cut out drill all the pocket holes there will be pocket holes along the top around the support, beam and down the back side. Don'T worry all those pocket holes will be covered up with the side pieces. In the end, once the sides are done, cut out the back frame and drill in the pocket holes along the top and along to each end. Now it's time to build the support beam. Rip the redwood 2x4 down and then attach another piece of plywood to it, glue the plywood to the redwood and screw it together with some wood screws.
Next drill, the pocket holes to one side of the beam all facing the same direction, cut the middle support block to link and attach it to the middle of the beam with glue and pocket screws. Now it's time to assemble the frame start by screwing the sides to the back make sure to keep all the pocket holes on the outside of the frame. Now install the beam attach the middle support to the back with wood screws through the back to make this easier set. This part up on a sawhorse and not the frame set up the seat piece on two or three sawhorses, with the good side down glue and screw.
The second piece of the seat together now turn the base upside down on top of the seat and glue and screw the frame to the seed through the pocket. Holes on the beam side and back next attach the back, lay the backdown and line up. The frame leaving three-quarters of an inch on each side of the frame glue it in place and hold it with clamps, while screwing it together through all the pocket holes on the side.
You can also screw together up high underneath the seat where the screws will be hidden now glue on the side pieces, add any other screws under the frame where they can be hidden. You can start with the left side, then finish up on the right side with the last two pieces. While the sides are drying attach some additional blocking and add a quarter-inch cover underneath the bench with wood screws, this will help keep out any unwanted pests like Hornets or wasps from hiding behind the beam, but this is optional with everything in place now, it's time to Fill any holes with Elmer's probe on stainable wood filler. Let that dry then sand everything smooth. Now you can stain it and finish it as you desire there.
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