Step 1
Trace MDF templates on top of the plywood, splitting the template into a few pieces to reduce material waste.
Step 2
Drill two holes on the inside of the outline to allow easier cutting with the jigsaw.
Step 3
Cut along the traced lines with the jig saw, cutting 1/8-1/16th of an inch outside of the outlines so that the lines can be refined.
Step 4
Attach the mdf template to the plywood using small screws.
Step 5
Use the router with the flush trim bit to trim the plywood to the exact size without using a CNC tool.
Step 6
Drill ½” Holes across the cutout plywood piece and remove the screws to detach the mdf template from the plywood.
Step 7
Attach two layers of the plywood together using wood glue and inserting ½” dowels into the holes made in the previous step. Trim the dowels so that they lay flush. Clamp the pieces together while the wood glue dries.
Step 8
Glue together the complex joints and corner pieces using wood glue and allow the glue to cure. Attach these pieces to the straight pieces that go in between with wood glue, building the loop that goes under the cushion first.
Step 9
Once both of the pieces have been built, clamp everything together using spring clamps and weight for stability.
Step 10
Once everything has cured, apply wood putty where there are any gaps in between the joints. Sand all over to finish once the wood putty has dried down. Use the palm router to round out all of the corners.
Step 11
Use a mini belt sander to sand all the inside corners and edges.
Step 12
Use a circular saw to cut linear supports that will go under the cushions and desk. Use the router to the round over the edges to match the other pieces
Step 13
On the short pieces, drill pocket holes.
Step 14
Use corner clamps to secure the short pieces to the long pieces, then screw them together using the pocket holes
Step 15
Use a circular saw to cut pieces from a full piece of plywood to use for the seat back rest and desk.
Step 16
Use a cup to trace quarter circles on the edges of these pieces, then use a jigsaw to cut the quarter circles out. Smooth out the edges using a sander.
Step 17
Use a router to round out the edges.
Step 18
Sand all of the pieces with a high-grit sand paper to prep for wood finishing coat.
Step 19
Wipe all of the dust off of the wood, then apply the wood finish to all of the wood pieces.
Step 20
Attach the support frame together under the seat using screws and clamps.
Difficulty Level - Intermediate
Sofa Desk
DIY Sofa Desk combination that does NOT require a CNC!
