This project was built and designed by Mike Montgomery from Modern Builds.
Mike reimagined a high‑end, chunky modern outdoor sofa using common lumber and accessible shop techniques, turning an expensive retail look into an affordable DIY piece.
The build focuses on clean proportions, hidden joinery, and modular assembly so the sofa can be moved and serviced over time.
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Design
The sofa blends chunky, structural elements with a slimmer, more modern face to create a high‑end look without high‑end cost. Mike was inspired by a retail design and distilled the visual cues—deep seat, low profile, and a floating reveal—into straightforward joinery and proportion choices.
Key to the aesthetic is the juxtaposition of thick visible backs and thinner front edges, which gives the piece presence while keeping lines clean. The result reads like contemporary outdoor furniture but is approachable to make in a home shop.
Lumber prep
Rather than using off‑the‑shelf rough lumber as‑is, Mike machined faces to remove rounded edges and expose continuous grain for a refined appearance. Flattening and thinning the boards improves fit, reveals better grain, and gives the project a more finished, furniture‑grade feel.
Addressing any cupping early prevents assembly frustration and keeps long runs square and stable. Working the stock before cutting parts also simplifies layout and ensures matching faces across paired components.
Joinery and assembly
The structural approach mixes glued joints with mechanical fasteners, then conceals the fasteners with dowels for a clean, joinery‑like finish. Pocket holes are used selectively where they speed assembly, and exposed screw holes are backfilled and trimmed flush to mimic solid joinery.
Mike also designed the sofa to come apart into sections by avoiding glue on a few strategic connections, allowing the heavy build to be moved and serviced. This modular thinking balances permanence where strength matters and removability where practicality matters.
Platform and support
The seat is a simple slatted platform that rests on internal stretchers, offering a bit of give that can improve cushion comfort. Spacing the slats and leaving a little bounce reduces the need for complex support while still providing durability for outdoor use.
Additional internal blocking and a discreet center support prevent sag over time, and raised feet create a floating reveal that keeps the form light while distributing weight across decking or patio surfaces. These small structural choices increase longevity without adding visual clutter.
Finishing and cushions
Before finishing, Mike raised the grain with a light water mist and followed with sanding to ensure a smooth surface ready for a water‑based outdoor sealer. Multiple thin coats of exterior urethane protect the wood while keeping the finish subtle and well suited to outdoor exposure.
Cushions with grippy backs and generous thickness complete the piece, fitting tightly into the frame to prevent sliding and wind issues. The cushion choice influences comfort more than anything else, so pairing the platform with quality outdoor cushions is essential to the finished experience.
Lessons and takeaways
This build demonstrates how modest material choices and a few shop techniques can create a look that rivals expensive retail pieces. Machining boards, hiding fasteners with dowels, and planning for disassembly all lift the perceived quality without drastically increasing cost.
The project is a solid example of accessible design: proportion and execution matter more than exotic materials. Readers can adapt the methods—slat spacing, hidden fasteners, modular connections—to different scales and aesthetics while keeping the same functional benefits.
Please support Mike by visiting his website: https://www.modernbuilds.com/.