Return to Projects Listing
DIY Plywood Sofa
DIY Plywood Sofa
DIY Plywood Sofa
  • DIY Plywood Sofa
  • DIY Plywood Sofa
  • DIY Plywood Sofa

DIY Plywood Sofa

This DIY modern plywood sofa is made out of 2-1/2” sheets of ¾” plywood from home depot. The cushions are made out of foam from foambymail.com I bought the leather to cover the foam cushions from tandyleather.com

View Project PDF

Videos


Steps


Medium 7a563b94 195e 4623 925a 00363ac2bc4a

STEP 1: Rip the plywood
I installed a new fresh plywood blade on my 6 ½” cordless circular saw. I want nice clean cuts and I got great results with this Diablo blade. http://www.homedepot.com/p/Diablo-6-1-2-in-x-40-Tooth-Finish-Plywood-Saw-Blade-D0641R/202035229
I set up the sheet of plywood on sawhorses and 2x4s. The 2x4s elevated the plywood above the sawhorses and ensured that my circular saw blade would not hit the sawhorses. I clamped a straight edge to the plywood to make sure my cuts were straight.


7a563b94 195e 4623 925a 00363ac2bc4a
×
Medium 8815439f f8fd 4653 9f95 07cbeb3ac4d2

STEP 2: Cut the plywood strips to length
I set my circular saw blade and a speed square to cut the plywood strips to the appropriate lengths.


8815439f f8fd 4653 9f95 07cbeb3ac4d2
×
Medium 663f27aa cd46 48a9 8fe0 38ac91a0f975

STEP 3: Glue the strips together
I used wood glue and clamps to turn the strips of plywood into two long beams that will make up the front and back of the frame for the sofa.


663f27aa cd46 48a9 8fe0 38ac91a0f975
×
Medium da0d341c 1257 48fe a514 1bb962e3b89a

Step 4. Assemble the frame.
I cut pieces to fit in between the front and back beams and then glued and screwed them together. I kept adding overlapping layers of plywood making sure that no screw heads show from the top.


Da0d341c 1257 48fe a514 1bb962e3b89a
×
Medium bcf5036c 0a41 4eb4 ac02 d1c1bbc9ec28

Step 5. Sand the frame. I sanded the frame with my orbital sander to make all the plywood edges flush and smooth.


Bcf5036c 0a41 4eb4 ac02 d1c1bbc9ec28
×
Medium 9a34a7e8 40a0 41a7 a079 7673fd966d94

STEP 1: Rip the plywood
I installed a new fresh plywood blade on my 6 ½” cordless circular saw. I want nice clean cuts and I got great results with this Diablo blade. http://www.homedepot.com/p/Diablo-6-1-2-in-x-40-Tooth-Finish-Plywood-Saw-Blade-D0641R/202035229
I set up the sheet of plywood on sawhorses and 2x4s. The 2x4s elevated the plywood above the sawhorses and ensured that my circular saw blade would not hit the sawhorses. I clamped a straight edge to the plywood to make sure my cuts were straight.


9a34a7e8 40a0 41a7 a079 7673fd966d94
×
Medium c2896dc2 04a8 45a3 b7f3 740cf24dca41

Step 6 Add the legs
I aadded the legs in two stages. First I glued together 3” wide strips of plywood 2 or 3 at a time. I then glued and screwed these pieces to the underside of the frame.


C2896dc2 04a8 45a3 b7f3 740cf24dca41
×
Medium 6bc6b2b7 566d 4a1e 8126 b5daca7bfd61

STEP 2: Cut the plywood strips to length
I set my circular saw blade and a speed square to cut the plywood strips to the appropriate lengths.


6bc6b2b7 566d 4a1e 8126 b5daca7bfd61
×
Medium 409c213d bedb 440d 9419 bf4ce287262f

Step 7. Add support beam
I clamped down a straight edge and then cut strips off of the plywood to use as supports for the underside of the table. I also cut off the corners to make additional supports and to give the tabletop a cool shape.


409c213d bedb 440d 9419 bf4ce287262f
×
Medium 7ba6aaad ca4a 40bf ad5b 5892ae4a4fe2

STEP 3: Glue the strips together
I used wood glue and clamps to turn the strips of plywood into two long beams that will make up the front and back of the frame for the sofa.


7ba6aaad ca4a 40bf ad5b 5892ae4a4fe2
×
Medium d1a06604 8172 4d8a 9934 5c65e76573f2

Step 4. Assemble the frame.
I cut pieces to fit in between the front and back beams and then glued and screwed them together. I kept adding overlapping layers of plywood making sure that no screw heads show from the top.


D1a06604 8172 4d8a 9934 5c65e76573f2
×
Medium 11243f14 0a9c 49d4 a487 95928455578f

Step 5. Sand the frame. I sanded the frame with my orbital sander to make all the plywood edges flush and smooth.


11243f14 0a9c 49d4 a487 95928455578f
×
Medium cff44c94 09de 4dcb 96ed ad452df2f020

Step 8. Add angled filler strip
I ripped a thin strip of ¾” plywood with the blade on my circular saw set to a 45 degree angle. I then glued this strip to the front beam. I tested the fit for the seat piece of plywood and then sanded down the angled strip a bit so that I got a nice fit with the seat piece.


Cff44c94 09de 4dcb 96ed ad452df2f020
×
Medium b8a3774e 0da8 4942 937c 82b7a2dfa0d1

Step 9 screw in the seat
I screwed the seat piece of plywood in place. This piece sticks out past the frame a little bit so I just sanded it flush with my orbital sander.


B8a3774e 0da8 4942 937c 82b7a2dfa0d1
×
Medium a78cf5b3 d1af 4b70 8220 23f22af52270

Step 6 Add the legs
I aadded the legs in two stages. First I glued together 3” wide strips of plywood 2 or 3 at a time. I then glued and screwed these pieces to the underside of the frame.


A78cf5b3 d1af 4b70 8220 23f22af52270
×
Medium 0667305d 2632 42e9 b735 f9bb5d412602

STEP 10: add the back rest
I set the back rest in place and then held a 3” wide strip of plywood to the angle of the back rest and traced the line. I cut triangular pieces to fit between the backrest and frame.


0667305d 2632 42e9 b735 f9bb5d412602
×
Medium 7a923e13 e434 4bf8 9069 71d27115601c

Step 11: add back rest supports
I glued 5 layers of plywood triangles together and then sanded the edges flush. I then glued and screwed these supports to the back rest. I did not screw them to the frame because I want the sofa to come apart so that it is easy to move.


7a923e13 e434 4bf8 9069 71d27115601c
×
Medium dcc18ced 6113 4e3d a20c c1004095a0f0

Step 12 seal the plywood
I sealed the plywood with minwax polycrylic in a satin finish.


Dcc18ced 6113 4e3d a20c c1004095a0f0
×
Medium f4c821b1 57c3 4721 8ab7 9347cfc6df98

Step 7. Add support beam
I clamped down a straight edge and then cut strips off of the plywood to use as supports for the underside of the table. I also cut off the corners to make additional supports and to give the tabletop a cool shape.


F4c821b1 57c3 4721 8ab7 9347cfc6df98
×

DIY Leather cushions
I used the same cushion technique that we developed for the ZigZag sofa which you can see here: http://www.homemade-modern.com/ep108-zig-zag-sofa/


×
Medium 184327b1 a8c3 4698 8930 bbf6addd46d6

Step 8. Add angled filler strip
I ripped a thin strip of ¾” plywood with the blade on my circular saw set to a 45 degree angle. I then glued this strip to the front beam. I tested the fit for the seat piece of plywood and then sanded down the angled strip a bit so that I got a nice fit with the seat piece.


184327b1 a8c3 4698 8930 bbf6addd46d6
×
Medium d2dfabb0 8377 4cd6 8db7 19213417a485

Step 9 screw in the seat
I screwed the seat piece of plywood in place. This piece sticks out past the frame a little bit so I just sanded it flush with my orbital sander.


D2dfabb0 8377 4cd6 8db7 19213417a485
×
Medium 63b7a2d6 83e9 4b6b a8b5 20687f28b845

STEP 10: add the back rest
I set the back rest in place and then held a 3” wide strip of plywood to the angle of the back rest and traced the line. I cut triangular pieces to fit between the backrest and frame.


63b7a2d6 83e9 4b6b a8b5 20687f28b845
×
Medium 31d9421c 448f 4d95 88a1 21d8a4e32644

Step 11: add back rest supports
I glued 5 layers of plywood triangles together and then sanded the edges flush. I then glued and screwed these supports to the back rest. I did not screw them to the frame because I want the sofa to come apart so that it is easy to move.


31d9421c 448f 4d95 88a1 21d8a4e32644
×
Medium ec3a0a7d b25e 4c16 b69f b8d5eae1c113

Step 12 seal the plywood
I sealed the plywood with minwax polycrylic in a satin finish.


Ec3a0a7d b25e 4c16 b69f b8d5eae1c113
×

DIY Leather cushions
I used the same cushion technique that we developed for the ZigZag sofa which you can see here: http://www.homemade-modern.com/ep108-zig-zag-sofa/


×
View All Steps
spacer

Comments (0) Sign In To Follow Project


View All Comments
spacer

Homemade Modern

Homemade Modern

All Projects | Profile


  • share

Project Information

Difficulty: Intermediate
Category: Furniture

Materials Used:

  • leather

  • foam cushions- lux foam with dacron wrap 3" x 18" x 66"

  • foam cushions- lux foam- high quality with dacron wrap. 3" x 24" x 66"

  • minwax polycrylic

  • 2-1/2 sheets of 3/4" thick sanded pine Plywood


also by Homemade Modern


Related Projects



Forgot your password? Click here.

Don't have a RYOBI Account? Sign Up Now.

×