In this guide, Anthony and B Barker from Wood Pack DIY share their expertise on building a stunning outdoor sofa, perfect for enhancing any patio space.
Materials Needed:
- 4×4 lumber for legs
- 2×4 lumber for the frame
- 1×3 lumber for slats and supports
- Wood glue
- Screws (various sizes)
- Beadlock tenon system
- Leg levelers
- Stain and spar urethane for finishing
Tools Required:
- Table saw
- Router
- Drill
- Clamps
- Sander
- Kreg jig for pocket holes
- Tack cloth
Step 1: Create the Legs
To start, the legs are constructed similarly to those used in the patio chairs and coffee table. The 4×4 lumber is cut to a more manual shape, and a bevel is created using a table saw blade set at an angle. This gives the legs a refined look while also reducing weight.
Step 2: Join the Legs
The legs are joined together using the beadlock jig, which, although requiring extra work compared to other methods, is manageable for most DIYers. Careful clamping ensures that the joints fit snugly, and a chisel is handy for cleaning up any excess material.
Step 3: Prepare for Glue Up
After the joints are ready, the next step is to apply wood glue to secure the connections. Clamping the pieces together allows the glue to set properly, while any imperfections can be smoothed out with a little extra sanding later.
Step 4: Build the Platform
For the sofa’s platform, it’s crucial to connect it to both the front and back legs for added stability. The frame is constructed with cross supports, and pocket holes are used in conjunction with beadlock tenons to ensure everything holds together securely.
Step 5: Assemble the Platform
Once the platform is framed, it’s time to assemble it. The pieces are clamped in place, and wood glue is applied at the joints. Pocket screws are used to reinforce the connections, keeping everything hidden from view for a clean finish.
Step 6: Attach the Backrest
The backrest is carefully measured and cut to fit snugly between the legs. Angles are cut on the supports to match the design of the sofa, and pocket holes are used to keep the assembly neat and tidy.
Step 7: Add Slats for Seating
Next, slats are added to the seating area. Each slat is secured with pocket holes to ensure they stay in place. The spacing between the slats is crucial for both aesthetics and comfort.
Step 8: Finishing Touches
With the assembly complete, it’s time to finish the sofa. A final sanding ensures a smooth surface, and a coat of stain is applied, followed by spar urethane for protection against the elements. Multiple coats may be necessary for a durable finish.
Final Thoughts
Once everything is dry, the outdoor sofa is ready to be placed in its new home. Bob Barker even gives it his stamp of approval! For those interested in building this sofa, detailed plans are available for purchase.