Weatherly Sofa

Submitted by Ana White on Tue, 04/19/2011 - 20:46
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The sofa for the Weatherly section.  Featuring large X styling, finials, and can work to create a sectional.

I'm pretty excited about today's post . . . but first, I gotta give you good reason why the piping on my cushions don't quite line up

You KNOW exactly what I'm talking about. 
Anyway, I find myself overly excited to post this plan today for two reasons: 1) Yay! that looks like a comfy spot to work once winter is finally over and 2) Got a sweet sweet deal to share with you on those cushions.
But before we get to the sweet deal on the cushions, how about the sweet deal on the frame?  I spent about $35 (not including screws and finishing supplies as I now buy these items in the biggest possible container I can lift by myself at Blue or Orange)?  Makes the cushion deal I'm about to tell you about seem not quite as sweet . . . 
About a year ago, I decided that I was madly in love with Restoration Hardware's Nantucket outdoor set, and had good intentions to build the sofa, chair and loveseat.  This was THE ONE for me.  Everyday, I would check Restoration Hardware's site, checking on the price of the cushions.  And one day, I sat down with the Ram, and asked if I could spend $650 on cushions for a sofa.  And he of course said yes, but I just never could justify the cost myself.  And so I gave up.
And then last week, I was looking for cushions for the Weatherly Sofa (this plan) and came across this deal - $189 and Free Shipping (even to Alaska) for these very cushions!  Pretty fond of the saying "you get what you pay for, unless it's in sweat" I even called Restoration Hardware to confirm this was the true price, for a set of three cushions.  
But it wasn't until a giant box (well, actually two giant boxes) arrived at our door that I believed.  And when I opened that box, and saw the soft Sunbrella fabric, the piping, the thick cushions, I couldn't wait to post this plan, in hopes that some of my friends online like the color Navy with white piping in Sunbrella Canvas (Charcoal is also on sale, and Mocha in the Sunbrella Twill).  
One note, I did design this plan to fit standard 24" x 24" cushions, and the Restoration Hardware Nantucket cushions are approximately 24" x 27" - which fit good with the sofa alone - but might not line up right if you choose to add the loveseat and create a sectional.  Might be a better idea to stick with 24" x 24" cushions that are available everywhere.


Shopping List

7 - 1x2 @ 8 feet long

7 - 2x2 @ 8 feet long
3 - 2x3 @ 8 feet long
2 - 2x6 @ 8 feet or stud length
4 - 1x3 @ 8 feet long
4 - Unfinished wood curtain rod finials
Common Materials
2 1/2 inch screws
1 1/4 inch finish nails
120 grit sandpaper
wood conditioner
paint brush
Cut List

10 - 1x2 @ 20 13/16" (Large X pieces - cut both ends at 30 degrees off square, ends PARALLEL to each other)

20 - 1x2 @ 10 3/8" (Small X Pieces - cut both ends at 30 degrees off square, ends NOT PARALLEL to each other, longest point to longest point measurement)
10 - 2x2 @ 12 1/8" (X Ends)
7 - 2x3 @ 23" (Tops/Bottom of X)
2 - 1x2 @ 23" (Top of Sides)
4 - 2x2 @ 33 1/2" (Legs)
2 - 2x6 @ 23" (Side Aprons)
2 - 2x6 @ 72" (Front/Back Aprons)
2 - 2x2 @ 17 1/4" (Back Centers)
1 - 2x3 @ 72" (Back Top)
1 - 1x2 @ 72" (Back Top Trim)
2 - 2x2 @ 72" (Cleats)
16 - 1x3 @ 23" (cut to fit - slats)
Tape Measure
Speed Square
Safety Glasses
Hearing Protection
Kreg Jig
Miter Saw
Brad Nailer
Power Sander
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!


Step 1

Start by nailing the shorter angled 1x2 pieces to the longer 1x2 pieces as shown above. Test to make sure that you can fit a 1x2 in the middle (see next step). You will need to build ten of these.

Step 2

Then take the ten halves and make five big Xs as shown above. Lay the Xs on top of each other to make sure they match.

Step 3

On all five of the Xs, attach the 2x2s @ 12 1/8" as shown above. You can either use the Kreg Jig™ (set for 3/4" stock and 1 1/4" pocket hole screws - it's okay if the pocket hole "hangs over" the edge of the board) or 2 1/2" screws or finish nails and glue to attach.

Step 4

On two of the X pieces, attach tops and bottoms from 2x3s as shown above. I used the Kreg Jig™ as shown above.

Step 5

Step 6

Now add legs to the two ends that you are working on as shown above.

Step 7

Finish the two ends by adding the 2x6 as shown above. You can either use the Kreg Jig™ or 2 1/2" screws countersunk from the outside. Set the two ends aside.

Step 8

Next, you will need to construct the back. I laid all the pieces out and marked the joints, and drilled pocket holes with my Kreg Jig™ set for 1 1/2" stock, with 2 1/2" pocket hole screws. Check to make sure everything is square. This is definitely the longest step, but take your time - it's important to get this back right.

Step 9

Once your back is finished, you can attach it to the sides. I used 2 1/2" screws and glue. Adjust for square.

Step 10

Finally, attach the front rail.

Step 11

Now it's time for the cleats. One trick that I did different than the loveseat, I lowered the back cleat a tad, so the seat reclines slightly. I found this made the seat much more comfortable.

Step 12

Now lay your seat slats. Screw down. (image from Loveseat) You may need to add more seat slats depending on the firmness (or softness) of your cushions.

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.
Finish Used
Primer and two coats of high gloss white exterior by Valspar. I added curtain rod finials to the posts for a little extra decoration.



Thu, 04/21/2011 - 03:22

I love love love it!  And I love the navy cushions.  It looks fantastic!  

Guest (not verified)

Sat, 05/14/2011 - 22:10

Hey Ana I'm just curious as to what the widths of your cushions are? The ones I find at stores in my area seem to come no thicker than 3", so I'm wondering if I should adjust the plans a little to make up for that since yours look to be quite thick. Thanks!!


Mon, 05/16/2011 - 09:26

Hi Ana, do you know what the weight limit would be per couch? I would really like to build a whole sectional, but it will have to be able to hold bigger people and I wondered if I would have to reinforce by using thicker lumber like 4x4s instead of 2x2s, etc. I would appreciate any advice!

Ana (not verified)

Mon, 05/16/2011 - 09:56

As far as a weight limit . . . I can't give you an exact number, but I can tell you my family has no issue, and the RAM weighs over 200 pounds.

If you are concerned about weight, I would recommend adding additional "legs" under the seats. You would do this by running 2x4s (two would be good) below the slats/cleats, and then adding a leg (could be a 2x4) under it. That way the weight is resting right on a leg, but you do not have to change the styling.

Guest (not verified)

Tue, 05/17/2011 - 14:01

I am having trouble with step one and the cut measurements I did. I did the cut list exactly as described for the 1x2 pieces and they look exactly like the picture shows, but if you leave the 1.5" gap in between for the crossing board, the wood does not match up on the two layers and hangs off the edge. I have re-measured everything several times and had others look at it too. Is the 1x2 that is cut 20 13/16" supposed to actually be longer and it was a typo? It seems I am off by about 3/4". Any help from Ana or anyone else is appreciated! I love this design and am eager to figure something out and make it work!

Guest (not verified)

Sun, 05/22/2011 - 18:59

The measurements worked for me. Are your angles right? Also heads up,paint/stain this before you put it together. I couldn't make up my mind on a color and painting it assembled is a nightmare...but it's a dream to have this awesome sofa!

Thank you Ana for all your hard work. You're amazing!

Guest (not verified)

Sat, 06/11/2011 - 13:40

Bummer. I have the exact same problem with step one! Did you figure out the problem because my measurements are the exact same and I can't figure out what happpened. Did I use the wrong size wood?

Urg. Thanks for any advice anyone can give. FYI, Walmart has 24"x24" cushions for $24.00 each. They are 5" thick too. Just ordered some hoping I could get the sofa made before they get here.

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