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A full sofa built as a hinged storage box with a foam-cushion top, upholstered with batting, burlap, and a sewn slipcover.
| Part | Qty | T × W × L | Material | ✓ |
|---|---|---|---|---|
| Back frame top | 1 | 1 1/2" × 3 1/2" × 72" | Pine 2x4 | ☐ |
| Back frame bottom | 1 | 1 1/2" × 5 1/2" × 72" | Pine 2x6 | ☐ |
| Back frame legs, tapered Tapered as shown in step 1. | 4 | 1 1/2" × 5 1/2" × 24" | Pine 2x6 | ☐ |
| Back frame cross supports | 3 | 1 1/2" × 3 1/2" × 22" | Pine 2x4 | ☐ |
| Back panel (lower, plywood) | 1 | 1/4" × 17 5/8" × 72" | 1/4" plywood | ☐ |
| Seat panels (top and bottom) | 2 | 1/4" × 30" × 72" | 1/4" plywood | ☐ |
| Base sides | 2 | 1 1/2" × 9 1/4" × 72" | Pine 2x10 | ☐ |
| Base cross members | 3 | 1 1/2" × 9 1/4" × 27" | Pine 2x10 | ☐ |
| Base aprons, long | 2 | 1 1/2" × 1 1/2" × 65" | Pine 2x2 | ☐ |
| Base aprons, short | 2 | 1 1/2" × 1 1/2" × 28 1/2" | Pine 2x2 | ☐ |
| Sofa feet | 4 | 3 1/2" × 3 1/2" × 5" | Pine 4x4 | ☐ |
| Item | Qty | ✓ |
|---|---|---|
| Foam camping pad or cushion, 30" x 72" x 3-1/2" | 1 each | ☐ |
| Paint drop cloth, 9x12 Slipcover fabric. | 1 each | ☐ |
| Upholstery batting | 6 yard | ☐ |
| Pillow stuffing, 20 oz bag | 2 each | ☐ |
| Burlap | 2.5 yard | ☐ |
| Staples | 1 box | ☐ |
| Wood screws, 3" (or 2" pocket hole screws) | 1 box | ☐ |
| Wood screws, 1-1/4" | 1 box | ☐ |
| Wood glue | 4 oz | ☐ |
| Spray adhesive | 2 can | ☐ |
| Pine, 2x4, 8 ft | 2 each | ☐ |
| Pine, 2x6, 8 ft | 2 each | ☐ |
| Pine, 2x2, 8 ft | 2 each | ☐ |
| Pine, 4x4, 2 ft Sofa feet. | 1 each | ☐ |
| Pine, 2x10, 12 ft | 1 each | ☐ |
| Pine, 2x10, 8 ft | 1 each | ☐ |
| Plywood, 1/4", 4x8 sheet | 2 each | ☐ |
| Hinges, heavy duty | 1 pair | ☐ |
| Hinge support strap Keeps the cushion from collapsing forward. |
Tools: Drill / Driver. Materials: Wood glue, Pine, 2x4, 8 ft, Pine, 2x6, 8 ft
Screw the back frame together with 3" screws or 2" pocket hole screws, tapering the legs as shown. Use glue and adjust for square.
Tools: Drill / Driver. Materials: Wood glue, Plywood, 1/4", 4x8 sheet
Attach the 1/4" plywood to the lower portion of the back frame with 1-1/4" screws and glue.
Tools: Staple Gun. Materials: Upholstery batting, Burlap, Spray adhesive
Wrap the upper portion of the back not covered by plywood with burlap, stapled tight along the bottom edge. Use spray adhesive to glue batting over the burlap, following the adhesive can's instructions for the best bond.
Materials: Upholstery batting, Spray adhesive
Glue batting pieces to the ends of the back frame with spray adhesive, then trim to fit. Set the finished back assembly aside.
Tools: Staple Gun. Materials: Foam camping pad or cushion, 30" x 72" x 3-1/2", Paint drop cloth, 9x12, Upholstery batting, Spray adhesive, Plywood, 1/4", 4x8 sheet
Use spray adhesive to attach the foam pad to one plywood seat panel, then attach batting over the foam on the top, front, and sides. Sew a box cushion slipcover from the drop-cloth fabric — one piece 73" x 31", two pieces 31" x 6", and two pieces 73" x 6". Fit the slipcover over the foam and staple the raw edges to the underside of the plywood, hiding the edges.
| 1 each |
| ☐ |
Overall cost: $$$. Lumber varies by region, species, and season, so we give a band rather than a figure.
Tools: Staple Gun. Materials: Paint drop cloth, 9x12
Cut and sew fabric strips for the front and side skirt, then staple in place, turning edges under to hide raw seams. Sew the back skirt pieces and fit over the back frame, turning under and stapling to the underside of the legs. Skipping the taper on the back frame makes every cut here square, which simplifies this step considerably.
Tools: Drill / Driver. Materials: Pine, 2x2, 8 ft, Pine, 2x10, 12 ft, Pine, 2x10, 8 ft
Build the base from the 2x10 sides and cross members — these carry the structural load, so don't worry about the thinner 2x2 aprons being weak; they only keep the fabric tucked under and give the feet something to screw to. Paint or stain the base.
Tools: Drill / Driver. Materials: Hinges, heavy duty, Hinge support strap
Screw the storage box to the back assembly, through the 2x10 back boards into the back's cross supports, using 3" screws. Flip over and screw the base to the underside of the sofa with 3" screws. Flip back over and attach the cushion top with hinges, supporting them with a strap so the cushion can't collapse forward.
Tools: Drill / Driver, Random Orbit Sander. Materials: Pine, 4x4, 2 ft
Attach the sofa feet to the underside of the base.
Sand any exposed wood surfaces and finish.
Materials: Paint drop cloth, 9x12, Pillow stuffing, 20 oz bag
Sew square box-cushion pillows measuring 36" wide x 4" deep x 18" tall: four pieces of fabric 37" x 19", four pieces 19" x 5", and four pieces 37" x 5" per pillow. Stitch right sides together into a box shape, leaving an opening to insert stuffing, then stuff and hand-stitch the opening closed.