Open the Foam The foam comes rolled up tight and should be opened right awaysoit can expand and takes its full shape.
Cut the2x10s and 2x4sI used my circular saw to cut the2x10s and 2x4sto length.Here are the measurements I used: (PDF Cheat Sheet)
Clamp the legs together and cut notches I clamped the2x10 leg pieces together and then marked the locations ofthe notches I needed to cut.I set the blade onmy circular saw tothe maximum depth and made a series of cuts.I then broke off the slivers of wood that remained.
Finish the notches The circular saw doesn’t cut deep enough so I finished the notches by drilling holes and then using a chisel to remove the wood.The notches should be big enough for a 2x4to fit in.
Sand the pieces I sanded all the pieces with 120 grit and then 220 grit sandpaper using my orbital sander.I rounded over the edges and corners so that there where no sharp corners.
Assemble the inner frame The inner frame is made out of pieces of2x4.I pre-drilled holes before screwing the pieces together.This prevents the 2x4s from splitting.
Assemble the base I assembled the rest ofthe base around the inner frame.The fit was pretty tight so I used a mallet toget the pieces inthe right places.I then flipped it over and screwed it all together.
screw onthe2x10sI screwed 2 pieces of2x10tothe base after measuring to make sure they were centered.
assemble the back supports I made the back supports by screwing 3 pieces of2x4 together these two back supports go around the2x10 legs and will hold upthe backrest for the sofa.
attaché the backrest I screwed the backrest piece of2x10tothe back supports after measuring to make sure itwascentered.I then raised the backrest into place and then secured itby screwing through the2x4sinthe backrest and into the2x10 legs.
drill holes for the bungee cords I used bungee cords to secure the covering over the foam.I drilled holes inthe2x4sso that the cords could go through them.
cover the cushions I cut an old blanket into pieces to use to cover the foam.I wrapped the blanket around the foam and then secured itin place using the bungee cords.I experimented with a blue fleece blanket and with a grey knit blanket.The fleece worked best but the color was a bit too much.
Bonus options: Option 1: Use string with shorter bungee cords If you want to make this sofa even more affordable you can use short bungee cords and string instead of longer and more expensive bungee cords