This project was created by Woodbrew, and it showcases how to build an impressive sofa using just one sheet of plywood and some hairpin legs. Perfect for anyone looking to enhance their living space with a custom piece.
Materials Needed
- 1 sheet of 4′ x 8′ plywood
- Hairpin legs (custom size)
- Fastcap screws
- Wood glue
- Poly coat finish
Tools Required
- Makita track saw
- Table saw
- Drill
- Measuring tape
- Clamps
- Grinder (for screw adjustments)
Step 1: Cutting the Plywood
The first step in building this modern sofa is to take a full 4′ x 8′ sheet of plywood. It’s crucial to get the measurements right. The creators suggest cutting the sheet roughly in half to make handling easier when doing the rest of the cuts. Using a Makita track saw, they ensure a straight and precise cut.
Step 2: Preparing the Panels
After cutting the plywood, the next step is to prepare the back and bottom panels. The back panel will serve as the support for your back, while the bottom section is where you’ll sit. It’s essential that these two pieces are exactly the same length. To achieve this, lay one piece on top of the other and trace the outline to ensure uniformity.
Step 3: Cutting the Side Panels
Next, it’s time to cut the side panels. A 10-degree angle is required for the backrest, so accurate measurements are essential to ensure everything aligns correctly. The creators opted to use the track saw again for this step, although a miter gauge on a table saw can also work well.
Step 4: Assembling the Sofa Frame
With all the pieces cut, it’s time to assemble the frame. The creators use Fastcap screws, which feature a flush trim drill bit system that creates a countersink for a clean look. They intentionally leave these screws exposed to add a design element to the sofa.
Step 5: Installing the Back Piece
The last piece of the frame is the back panel, which has all the holes pre-drilled for easier installation. This is crucial for ensuring stability and support when the sofa is in use.
Step 6: Attaching Hairpin Legs
Next, the hairpin legs are installed. The creators mark a 1.5-inch mark from either side to ensure they are positioned correctly. The legs are custom-made and provide a sleek, modern look to the sofa.
Step 7: Final Touches
Sometimes unexpected challenges arise, such as screws being too long. In this case, the creators used a grinder to trim them down. After ensuring the legs are securely attached, they apply three coats of poly coat to preserve the original plywood appearance.
Step 8: Adding Cushions
Finally, the creators recommend using outdoor bench cushions for added comfort. They designed the sofa to accommodate standard sizes, giving you plenty of options when selecting cushions.
If you decide to build this sofa for yourself, detailed plans are available here: https://www.woodbrew.tv/store/p/plywood-sofa-plans. With just one sheet of plywood, this project not only looks great but also saves space and money. Happy building!