2x4 Sofa DIY

     This is a very simple project, with just a few angle cuts. I recommend using a Chop-saw to cut the lumber to length, but if you don't have one, a circular saw or even a Jigsaw would work. I used webbing under the cushions that form the seat, but you could use plywood instead. If you do use plywood you can ignore the 1x2s that I used, as they are completely unnecessary when using a plywood base. Start by cutting everything to size, if you are making a sofa that is less than eight feet wide adjust the lengths of the boards accordingly. The first set of three cuts are the front and back cross members, those would be the only lengths to change to switch up the width of the sofa.

     Build two ends, that are mirrored images of each other. using a 40" board for the back, a 29" board for the front and a 26" board for the center support. The top of the center support should be fourteen inches from the ground You could at this point also install the 1"x26" at the top.

     The ends get joined together with the 2x6's. I used some lagbolts to make a super sturdy joint, but you could probably get by with construction screws. The tops of these boards are fifteen inches from the ground. You can also install the 2x4 and 1x4 on the back at this time. The 2x4 gets mounted at the top. The 1x4 could be put at a variety of heights, but I located it directly under the lower armrest support

     If you are going to use plywood for the base, just use a few of the 26" 2x4s and span the distance from the front and back of the sofa. Screw them in, measure and cut plywood to fit the space and then add your cushions, it's really that simple.

     If you are going to use webbing for the base install the 26" 2x4s to keep the tension from pulling the 2x6s in. Take the longer 1x2s and lay them ontop of the 2x4s you just installed and figure out the length you'll need for your webbing. I have no idea what length I used, because I never actually made a true measurement of it. I just wrapped a piece around the back board, and then left about an extra six inches on the front side and then used that one piece as a measure to cut all the other strips. There are many different ways to mount the webbing, and what I did may not be the best solution, so feel free to browse the web for other methods. Once you have all the webbing going from front to back it's time to add the 2' 2x4s to the inside ends and install the long strips of webbing, these will be woven through the shorter strips that are already installed.

     Once you have your chosen base installed the only thing left to do is get some cushions and make the armrest caps. These are the most complicated part of the entire build, so I've included a detailed 'drawing' of the design on them.

     This is cut from a 1x4. Cut a 45 degree angle on the three corners as show, set back one inch from the end. The remaining corner gets a chunk cut out for the 2x4. (In my designs I draw all lumber as the size it claims to be, not actual size, hence the reason for this diagram not being to scale.) Make two of these, and then install them on top of the arm rest supports. I tried just using brad nails originally, but one of my siblings accidentally pulled the arm rest off when they were getting out of the sofa, so I'd not recommend using that. I currently am using pocket screws, as they seem to be plenty sturdy, adding some glue wouldn't hurt things at all.

     That's really about all there is to it. I salvaged a lot of materials for this build, and didn't have to pay for anything other than the lumber and hardware. If you need to buy foam from a craft store you can easily expect to spend close to one hundred dollars for the foam alone, however this will still be way less than buying a sofa from any store.

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