If you’re looking for a stylish yet functional piece of furniture, Mike Montgomery from Modern Builds has got you covered. In this guide, he demonstrates how to create a modern sofa entirely out of 2x4s. This project is perfect for beginners and can be completed with limited tools.
Materials Needed:
- 2×4 lumber
- Wood glue
- Wood screws
- Clamps
- Circular saw
- 12-inch speed square
- 220 grit sandpaper
- Water-based polyurethane
- Cushions (available from Simple Cushions)
Step 1: Cutting the Panels
Mike starts by selecting his best-looking 2x4s for the side panels of the sofa. He cuts 14 pieces, each 25 inches long, using a circular saw with a finish blade to prevent tear-out. A 12-inch speed square ensures that all cuts are square.
Step 2: Creating the Mitered Frame
Next, he sets his circular saw to a 45-degree angle to cut a mitered frame that will go around the panel. Taking his time to sneak up to the cut ensures a perfect fit.
Step 3: Gluing the Panels
After ensuring the top and bottom plates fit well, Mike sands all the pieces to a smooth finish of 150 grit. He applies wood glue carefully to minimize squeeze-out and clamps the panels together, allowing them to dry overnight.
Step 4: End Grain Glue Up
For the next glue-up, he applies a coat of glue to the end grain, which is porous. He uses a silicone brush to spread it around, followed by a second coat before clamping everything down. Mike notes that this method may not account for wood movement, but he’s curious to see how it holds up.
Step 5: Laying Out the Cushion Placement
With the panels complete, he cuts templates to represent the cushion sizes, allowing him to mock everything up before assembly. He uses the speed square to mark the angles for the seat and backrest.
Step 6: Making Custom Brackets
Mike then makes custom brackets that will connect the horizontal slats to the leg assemblies. He emphasizes the importance of marking and cutting each piece to fit, as not all 2x4s are the same size.
Step 7: Sanding and Final Assembly
He sands the pieces as he goes, which saves time later. After cutting the slats to size, he checks the fit of the cushions to ensure everything is aligned correctly.
Step 8: Adding Legs for Height
To enhance comfort and aesthetics, Mike decides to add round legs using plugs he cut from a 2×4. This gives the sofa a floating look.
Step 9: Finishing Touches
After attaching the legs, Mike sands everything with 220 grit and applies water-based polyurethane to protect the wood while preserving its natural tone.
Step 10: Final Assembly and Cushion Placement
Once the finish dries, Mike places the cushions from his new company, Simple Cushions, on the sofa, giving it a comfortable and modern look.
This modern DIY sofa is not only stylish but also practical for any outdoor space. Mike’s detailed instructions make it easy for anyone to replicate this project.