Hey Remodelaholics! To start off our Plywood Pretty week, today I want to show you how to make a DIY Modern Plywood Outdoor Sectional Sofa. Be sure to check out all the #PlywoodPretty Challenge projects on our playlist and links below, and subscribe by email or RSS and follow along over on Facebook and Instagram with #PlywoodPretty so you won’t miss any of these new tutorials!
We designed this sofa for our deck. A couple things we considered when designing it was we wanted an L-shaped sectional sofa and a place to store our cushions during a storm to keep them dryer.
Each section of the sofa will be made out of two sheets of 3/4″ inch birch plywood.
DIY Modern Outdoor Sectional Sofa
Materials For One Sectional
- (2) 4 ‘x 8' x 3/4″ – Sheets of Birch Plywood
- (1) 4 ‘x 8' x 1/4″ – Sheet of Birch Plywood (optional)
- (1) 2 x 4 x 8’ – Redwood
- (55+) 1 ¼” – Kreg Jig Screws
- (12+) ¾” – wood screws (for optional bottom cover)
- (12+) 1 ¼” – wood screws (for optional bottom cover)
- (1+) Elmer's Carpenter's Wood Glue Max
- (1) Elmers Pro Bond Wood Filler
- Table Saw
- Miter Saw
- Circular Saw
- Kreg Jig
- Spring Clamps, (lots of them)
- Tape Measure
- 80/120/220 Sandpaper and Sanding Block
- (2+) Saw Horses
- Putty Knife
Plans with Dimensions
DIY Modern Plywood Sofa Sectional
Left Side View
Layout for Pocket Holes
Cut List (Length x Width x Thickness)
3/4″ Sheet One
- (1) 72 ⅜” x 24” x ¾” – Back
- (1) 24” x 23 ½” x ¾” – Right Outer Side
- (1) 70 ⅞” x 23 ½” x ¾” – Seat Top
- (1) 23 ½” x 8 ¾” x ¾” – Right Frame Side
- (1) 23 ½” x 8 ¾” x ¾” – Left Frame Side
3/4″ Sheet Two
- (1) 70 ⅞” x 23 ½” x ¾” – Seat Bottom
- (1) 23 ½” x 13 ¾” x ¾” – Right Inner Side
- (1) 23 ½” x 10 ¼” x ¾” – Left Outer Side
- (1) 69 ⅜” x 8 ¾” x ¾” – Back Frame
- (1) 70 ⅞” x 2 ½” x ¾” – Support Beam
- (1) 70 ⅞” x 2 ½” x 1 ½” – Support Beam
- (1) 9 7/8” x 2 ½” x 1 ½” – Middle Support Block
1/4″ Sheet – Optional
- (1) 69 3/8″ x 12″ x 1/4″ – Bottom Cover
To start off I used my circular saw to cut out the main pieces down, so that they're easier to manage for the the final cuts on the table saw.
Build the base frame of the plywood sofa sectional. First cut side frames to length and width. Then mark out where you will cut out the notch for a support beam, with a jig saw. The notch will be on the top center of the sides. See diagram below.
After the notch is cut out drill all the pocket holes. There will be pocket holes along the top, around the support beam and down the back side. Don’t worry all those holes will be covered up with the side pieces in the end.
Cut out the back frame and drill in the pocket holes along the top and along each end.
Build the support beam. Rip the redwood 2×4 down and then attach another piece of plywood to it, the same size, to make extra strong.
Glue the plywood to the redwood and screw it together with wood screws. Next drill in pocket holes to one side of the beam.
Cut the middle support block to length and attach it to the middle of the beam with glue and pocket screws.
Screw the sides on to the back. Make sure the keep all the pocket holes on the outside of the frame.
Now install the beam.
Attach the middle support to the back with wood screws through the back.
To make this easier, set this part up on a sawhorse and not the frame. Set up the seat piece on two or three sawhorses with the good side down. Glue and screw the 2nd piece of the seat together.
Use lots of clamps on the front side to glue it nice and tight. This will close of any gaps between the two layers.
Now turn the base upside down on top of the seat, that is upside down, and glue and screw the frame to the seat through the pocket holes on the beam, sides and back.
Attach the back. Lay the back down and line up the frame leaving ¾” on each side of the frame. Glue it in place and hold with clamps while screwing it together through all the pocket holes on the sides. You can also screw it together up high under the seat where the screws will be hidden.
Glue on the side pieces. Add any other screws under the frame where they can be hidden. You can start with the left side then finish up on the right with the last two pieces.
While the sides are drying, attach some additional blocking and add the ¼” cover underneath the bench with wood screws. This will help keep out any unwanted pests, like hornets or wasps from hiding behind the beam, but this optional.
Fill in any holes with Elmer’s Pro Bond Wood Filler, let that dry then sand everything smooth.
Don't forget to remove the tags before sanding and finishing!
Stain and finish as desired. We will be adding many coats of outdoor varnish to make it water tight.
There you have it! Your very own plywood sofa sectional. Now you can just lay back and enjoy your handy work. We are really loving ours!
If you are wondering where the cushions are from, please check out the Outdoor Sofa Sectional Reveal here!!
Check out all the #PlywoodPretty challenge posts here:
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farmhouse sign | Our Crafty Mom
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kids chairs with storage | Our House Now a Home