Simple White Outdoor Sofa

Submitted by Ana White on Mon, 06/06/2011 - 00:00
Difficulty
Intermediate
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About Project

An outdoor sofa DIY plan inspired by Restoration Hardware Nantucket collection. Features relaxed seats with modern styling and deep cushions. This simple free easy step by step plan is an affordable alternative to designer furniture.

Thank you thank you thank you for this sofa!

You see, I've dreamed of having a beautiful outdoor sofa set for years now, specifically Restoration Hardware's Nantucket set.  But we are just an average family on an average budget, and I'm just an average mom who always knows there's somewhere better to spend money than on dream patio furniture.  So this sofa (and the pieces that will follow) have been a distant dream for me for a long long time.  
Now you are probably thinking that Ana, you build furniture for a fraction of retail cost, that IS what you do.  So what's the prob?

You see, I've been building furniture for quite some time.  But a few years ago, I would not have had the confidence to tackle such a project.  I would not have had the experience with Google Sketchup.  And I would not have the excuse to build yet another piece of furniture  :)

I can promise you, if not for this blog, and for you reading this blog, I would not have this sofa.  Thank you so much for challenging me and enabling me to better my own home.
And the best part is I hope some of you have an opportunity to build this outdoor sofa as well.  
The Ram and I worked on this project together.  Anyone else love working on projects with their DH?  I was just thinking how different our relationship might be if we didn't spend so much time together working on projects.  Although this was really a quick afternoon project.  Truly just a few hours.
And the frame itself was rather inexpensive to build - I'd say around $30 in lumber.  But those cushions . . . I purchased the cushions from Restoration Hardware for $189 with free shipping . . . and they've since marked the price up quite a bit . . . 
If you can sew, you can either purchase custom sized cushions (even darcon wrapped!) or you can purchase 24" widths of foam, in three 48" long sections.  
My cushions measure as follows:
Seat: 24" x 26 1/2" x 6"
Back 24" x 18" x 6"
From each of the 48" lengths, cut one seat and one back cushion.  
And here are a few sewing tutorials for box cushions that  I thought you might find useful
Good luck to you whichever route you take . . . and thanks again for helping me get my new sofa!  Love love it!
Dimensions

Preparation

Shopping List

3 - 2x6 @ 8 feet or stud length
2 - 2x4 @ 8 feet or stud length
3 - 2x2 @ 8 feet long
3 - 1x2 @ 8 feet long
1 - 1x6 @ 6 feet long
1 - 1x4 @ 6 feet long
8 - 1x3 @ 8 feet long

Common Materials
2 1/2 inch screws
1 1/4 inch finish nails
120 grit sandpaper
primer
wood conditioner
paint
paint brush
Cut List

4 - 2x2 @ 22" (Legs)
2 - 2x2 @ 34" (Arm Tops)
2 - 2x6 @ 31" (Side Aprons)
2 - 2x6 @ 72" (Front/Back Aprons)
2 - 2x4 @ 72" (Back Support/Seat Support)
2 - 1x2 @ 31" (Side Apron Top Trim)
2 - 1x2 @ 72" (Front/Back Apron Top Trim)
1 - 2x2 @ 72" (Front Cleat)
16 - 1x3 @ 25" (Seat Slats)
2 - 1x2 @ 16 1/4" (Back Slats - Ends)
12 - 1x3 @ 16 1/4" (Back Slats - Center)
1 - 1x6 @ 72"
1 - 1x4 @ 72"

Tools
Tape Measure
Speed Square
Pencil
Hammer
Safety Glasses
Hearing Protection
Kreg Jig
Drill
Circular Saw
Jigsaw
Brad Nailer
Power Sander
Level
Drill Bit Set
General Instructions

Please read through the entire plan and all comments before beginning this project. It is also advisable to review the Getting Started Section. Take all necessary precautions to build safely and smartly. Work on a clean level surface, free of imperfections or debris. Always use straight boards. Check for square after each step. Always predrill holes before attaching with screws. Use glue with finish nails for a stronger hold. Wipe excess glue off bare wood for stained projects, as dried glue will not take stain. Be safe, have fun, and ask for help if you need it. Good luck!

Instructions

Step 1

You will need to build two arms. I used the Kreg Jig with pocket holes set for 1 1/2" stock and 2 1/2" pocket hole screws and glue.

Step 2

Once the two arms are built, attach front and back aprons, and backrest support. I again used the Kreg Jig and 2 1/2" pocket hole screws and glue. Adjust for square.

Step 3

You can click any image for a larger view. The front cleat is a 2x2 and needs to sit 1/4" down from the top of the front apron. The back cleat is a 2x3, and sits flush to the bottom.

Side note - if you would like to increase the weight capacity of this sofa, simply add 2x4 "legs" to the 2x4 seat support, they would be about 9" long, and would just be screwed to the side of the 2x4 seat support, and act as hidden legs right where you might need them.

Step 4

The trim just makes things prettier. I used a nailer and glue.

Step 5

Step 6

Begin by marking the location of your slats and predrilling pocket holes set for 3/4" stock. Join using 1 1/4" pocket hole screws and wood glue. If you wish (we choose not to) you can round the top edge of the back with a jigsaw. Sand until smooth.

Step 7

Now the fun part! Slide the back in place, and then screw to the two 2x4s as shown above in the diagram. Make sure you use a countersink bit.

Finishing Instructions
Preparation Instructions
Fill all holes with wood filler and let dry. Apply additional coats of wood filler as needed. When wood filler is completely dry, sand the project in the direction of the wood grain with 120 grit sandpaper. Vacuum sanded project to remove sanding residue. Remove all sanding residue on work surfaces as well. Wipe project clean with damp cloth. 

It is always recommended to apply a test coat on a hidden area or scrap piece to ensure color evenness and adhesion. Use primer or wood conditioner as needed.

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