This project comes from Johnny Brooke at Crafted Workshop, who designed a stylish and functional sofa using just a single sheet of plywood. If you’re looking for a space-saving seating solution, be sure to check out Johnny’s YouTube channel for more woodworking inspiration and tutorials.
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Why Build a Plywood Sofa?
This modern sofa is a great option for small spaces where a full-sized couch might not fit. It provides a sleek and sturdy seating option while keeping materials and costs minimal.
By using a single sheet of plywood, the design remains simple yet strong. Laminated panels add durability, and the finished piece has a professional look with clean lines and smooth edges.
Preparing the Plywood
To begin the project, Johnny carefully breaks down the plywood into manageable pieces. Using a straightedge jig ensures precise cuts and helps maintain straight lines for a seamless assembly.
The first cuts define the sofa’s side panels, which are later laminated to create extra strength. Keeping everything aligned during this stage is essential for a sturdy final build.
Creating the Sofa Sides
Each side of the sofa consists of two plywood layers laminated together for added support. By using the first cutout as a template, Johnny ensures both sides are identical in shape and dimension.
After cutting, the edges are sanded smooth, with special attention to the inside corners. This step not only enhances the aesthetic but also prevents rough edges that could cause discomfort during use.
Assembling the Sofa Frame
Once the side panels are prepared, the back and seat panels are cut from the same sheet of plywood. Chamfering the edges gives the sofa a refined appearance, softening the overall design.
Johnny secures the seat and back panels to the side sections using power head screws. These fasteners not only hold the structure firmly but also contribute to the sofa’s modern, minimalist aesthetic.
Reinforcing the Structure
To ensure long-term durability, Johnny adds cross braces between the panels. These braces help distribute weight evenly and keep the sofa frame rigid over time.
Pocket holes are drilled into the braces for a secure attachment. This step prevents any shifting or wobbling, ensuring the sofa remains stable even with frequent use.
Finishing the Wood
Once the structure is assembled, every surface is sanded to remove rough spots and enhance the natural look of the plywood. Achieving a smooth finish is essential before applying any protective coating.
A water-based polyurethane is used to seal and protect the wood. Depending on the tools available, this can be applied with either a brush or a sprayer for an even, durable coating.
Constructing the Cushions
To make the seating comfortable, Johnny builds custom cushions from half-inch plywood and foam. Spray adhesive is used to attach the foam securely to the wooden base.
Cutting foam cleanly can be challenging, but using an electric knife provides precise and smooth edges. To create a softer look, chamfers are added to the foam before covering it with fabric.
Upholstering the Cushions
The foam is first wrapped in batting to add an extra layer of comfort and prevent sharp edges. Upholstery fabric is then stretched tightly over the cushions and stapled underneath for a clean and secure fit.
Careful attention is needed at the corners to avoid bunching or wrinkles. With some practice, achieving a smooth, professional finish becomes much easier.
Final Assembly and Details
Rubber feet are attached to the bottom of the sofa to prevent scratches on the floor. This small addition also helps with stability and keeps the plywood from direct contact with the ground.
The cushions are secured to the frame using screws, making them easy to remove or replace if needed. This design choice allows for future updates to the upholstery without modifying the entire build.
A Stylish and Practical DIY Project
This plywood sofa is a perfect blend of simplicity and functionality, making it an excellent project for any woodworking enthusiast. The streamlined design and easy construction make it accessible for those with basic tools and limited workshop space.
For a full breakdown of the build and detailed plans, visit Johnny’s website. If you’re interested in making this project, watching the full tutorial will provide step-by-step insights straight from the Johnny.