DIY Outdoor Sofa : Free Woodworking Plans!

I finished my new DIY Curved Floating Deck earlier this summer and then shortly thereafter I built a new DIY Planter as the first piece of decor for my new hangout space in front of the house.  In the center of the planter that I built, I had created a diamond design and decided to incorporate that design element into any new furniture pieces that I built to enhance my new outdoor digs! 🙂  Which leads me to my newest addition to my new deck space:  My DIY Outdoor Sofa!

 

DIY Outdoor Sofa : Wood List

Quantity	Board	Length
15	2×4	96″
2	2×6	108″

 

DIY Outdoor Sofa:  Supplies List

Compound Miter Saw	Kreg Jig Pocket Hole System	Drill Driver
Kreg 2-1/2″ Blue Kote Pocket Hole Screws	2-1/2″ Exterior Wood Screw	Countersink Drill Bit
Exterior White Paint, Satin Finish	Worn Navy Wood Stain	Outdoor Spar Urethane, Satin Finish
Weathered Wood Accelerator	Wood Filler	Outdoor Deep Seat Chair Cushion Set

 

DIY Outdoor Sofa:  Wood Cut List

Quantity	Board	Length
11	2×4	72″
2	2×6	72″
13	2×4	25 1/2″
2	2×4	30″
11	2×4	17 1/2″
8	2×6	12 3/4″ straight end to long end (one end cut at 45 degrees)
4	2×6	10 13/16″ x 7 5/8″ x 7 5/8″ half diamond (two sides cut at 45 degree angles)

 

DIY Outdoor Sofa Plans

1. Using the miter saw,  cut the boards to build the couch seat frame
   • Cut two 2×4 boards to 72″ in length each
   • Cut five 2×4 boards to 25 1/2″ in length each

 

2.  Drill two 1 1/2″ pocket holes in each end of one side of the five 25 1/2″ boards.

3.  Use wood glue and 2 1/2″ blue Kote pocket hole screws to attach the 25 1/2″ boards to the two 72″ long 2×4 boards.

4.  Cut the wood for the sofa side and legs

• Cut eight 2×4 boards to 25 1/2″ in length each.
• Cut two 2×4 boards to 30″ in length each.
• Cut eight 2×6 boards to 12 3/4″ from straight edge to long end, with one end cut to 45 degree angle
• Cut four 2×6 half diamonds measuring 10 13/16″ x 7 5/8″ x 7 5/8″ (two short sides are cut to 45 degree angles

5.  Using the Kreg pocket hole jig,  drill 1 1/2″ pocket holes into each of the 2×6 boards, using the picture below as a template

6.  Drill two 1 1/2″ pocket holes into each end of one side of two of the 25 1/2″ 2×4 boards (one board for each end of the sofa)

7.  Use wood glue and 2 1/2″ blue kote pocket hole screws to attach the 25 1/2″ 2×4 board with the pocket holes to two of the 25 1/2″ 2×4 boards that will form the legs.  The 25 1/2″ cross board should be attached so the bottom of the cross board is 9″ up from the bottom of each leg (see graphic below) for each side of the sofa.

8.  Using wood glue and 2 1/2″ blue kote pocket hole screws and 2 1/2″ exterior wood screws,  attach the 2×6 and 2×4 boards to form the design shown in the graphic below.  Attach the 25 1/2″ board directly above the 2×6 design using wood glue and by countersinking 2 1/2″ exterior wood screws (predrill with countersink bit) through the front and back of the 2×4 legs.

9.  Attach the 30″ board (will be the arm rest) to the top of the legs using wood glue and countersunk 2 1/2″ exterior wood screw (predrill with countersink bit).  Ensure that the right and left side of the couch are facing the correct direction (pocket holes should face towards inside of couch and the longer side of the armrest should extend over so it faces towards the front of the couch on each side.

 

10.  Next, attach the bench frame to the assembled sides/legs of the sofa.  The bench frame should be attached so the bottom of the frame is flush with the bottom 2×4 on the sofa sides.  (To get the seat frame up to the 9″ height so it is flush with the bottom 2×4 on the sides/legs, you can stack 6 spare 2×4 or 2×6 boards underneath some of the boards on the bench seat frame, and then clamp the bench frame to the side boards.)  Attach the seat frame to the sides using wood glue and 2 1/2″ exterior wood screws (predrill first).  Attach through the side of the end 2x4s on the seat frame into the sofa sides.

 

11. Cut the boards for the bench seat top

• Cut seven 2×4 boards to 72″ in length

 

12.  Attach the bench seat boards to the top of the bench seat frame using wood glue and 2 1/2″ exterior wood screws (predrill holes first). Leave a 2/3″ gap between each board and line the back and front boards with the edges of the bench frame.

 

13.  Cut the boards for the back of the couch.

• Cut two 2×6 boards to 72″ in length
• Cut eleven 2×4 boards to 17 1/2″ in length

 

14.  Drill two 1 1/2″ pocket holes into each end of one side of each 17 1/2″ 2×4 board.

15.  In addition, drill two 1 1/2″ pocket holes to the bottom side of two of the 17 1/2″ boards, the pocket holes will point to the right on one of the boards and to the left on the other boards (see graphic below), these are the end boards on the right and left side of the back of the couch.

16.  Drill three pocket holes into each end of one side of one of the 2×6 boards (see graphic below)

17.  Attach the 2×4 boards to the 2×6 boards using wood glue and 2 1/2″ blue kote pocket hole screws. Ensure that the 2×6 with the pocket holes is on the bottom, and ensure that the two 2x4s with pocket holes facing to the side are on the ends, with the pocket hole screw holes facing to the right on the right side and to the left on the left side.

18.  Attach the couch back to the couch frame and sides using wood glue and 2 1/2″ pocket hole screws.  Place the bottom of the couch back on the top of the seat, lining it up with the edge of the 2nd seat board to the back.  Lean the back so the sides line up with the back of the top of the back of the arm rests and use clamps to hold the back in place while it is being attached.

19.  Cut the boards to support the back of the couch.

• Cut two 2×4 boards to 72″ in length each

20.  Drill two 1 1/2″ pocket holes into each end of one side of each board.

21.  Using wood glue and 2 1/2″ pocket hole screws,  attach one of the boards at the bottom of the bench seat, immediately behind the bottom 2×6, attach the second 2×4 towards the top of arm rests (lower the board to the point where it sits flush with the back of the back legs).

22.  Attach the top and bottom 2×4 support boards to the bench seat back with 2 1/2″ exterior wood screws (predrill first).

23.  Fill all holes with wood filler (or you can use pocket hole plugs) and let dry completely.

24.  Sand the entire couch (start with a low grit sandpaper and then move up to a higher grit finishing sandpaper).

25.  To get the weathered white finish,  first brush on a coat of Varathane Weather Accelerator, avoiding the diamond areas as much as possible.

 

26. Apply Rustoleum Navy stain to the diamond pattern, on both the inside and outside portions of the couch sides.

27.  Once the navy stain has dried,  tape off the diamonds using painters tape.

27. Next apply a thin coat of exterior white paint using light brush strokes so the weathered coloring shows through slightly.

28.  Once the bench has been painted, remove the painters tape from the diamonds.

29.  Move the couch to its final location on my deck

30.  Add the cushions and enjoy!

Now, I need to build a matching coffee table and I think I might paint the planter with the diamond to match the couch…  What do you think,  keep it as is or paint to match??  I’d love to hear your thoughts!