This modern sofa was designed and built by Johnny Brook from Crafted Workshop, and it’s perfect for any space that needs a cozy seating solution without taking up too much room. Using just one sheet of ¾” plywood, Johnny demonstrates how to create a comfortable and aesthetically pleasing sofa that’s perfect for smaller areas.
Materials Needed:
- 1 sheet of ¾” Purebond plywood
- 1 ¼” Powerhead screws
- 2 ½” Powerhead screws
- General Finishes Enduro Var
- Wood glue
- Upholstery fabric (1.5 yards)
- 6 feet of 1” x 60” Medium Fiber Fill or batting
- Foam padding (2” for seat and back cushions)
- Spray adhesive
- Electric knife
Tools Required:
- Circular saw
- Jigsaw
- Router
- Drill
- Flush trim bit
- Chamfer bit
- Brad nailer
- Stapler
Step 1: Break Down the Plywood
The first step is to cut the ¾” plywood into the necessary pieces. Johnny uses a circular saw and a straightedge jig to make clean cuts. He emphasizes the importance of making precise cuts for the sides of the sofa.
Step 2: Create Side Panels
Each side of the sofa is made up of two laminated pieces of plywood. Johnny cuts one side piece and uses it as a template for the other three pieces. He ensures to round the corners slightly to fit the flush trim bit later.
Step 3: Assemble the Sides
Once the side pieces are cut, they are glued together with wood glue and held in place with Brad nails and clamps while drying. After the glue has set, Johnny flush trims the sides to ensure they are perfectly even.
Step 4: Cut Back and Seat Panels
The next task is to cut the back and seat panels. Johnny uses a chamfer bit in the router to add detail to the edges before attaching them to the sides with Powerhead screws.
Step 5: Add Cross Braces
To enhance stability, Johnny cuts and attaches cross braces beneath the seat. He drills pocket holes to secure them firmly in place, ensuring the sofa will support weight effectively.
Step 6: Sand and Finish
With the wooden structure complete, Johnny sands all surfaces up to 180 grit for a smooth finish. He then applies a water-based polyurethane using an HVLP system for a professional look.
Step 7: Create Cushions
Johnny cuts the bottoms for the cushions from half-inch plywood. He opts for two cushions for both the seat and back, attaching foam padding to the plywood using spray adhesive.
Step 8: Upholster the Cushions
Using batting and upholstery fabric, Johnny staples the fabric to the underside of the cushions, ensuring a tight fit without wrinkles. He shares that this was his first time doing upholstery, and it turned out well!
Step 9: Attach the Cushions
Finally, Johnny attaches the cushions to the sofa using screws, ensuring they are secure yet easy to remove for any future repairs. He adds rubber feet to the bottom to protect the floor.
Conclusion
And there you have it! A modern DIY sofa built with just one sheet of plywood, perfect for any space. For detailed plans and more information, check out Crafted Workshop’s website.