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The armless middle piece that turns two outdoor sofas into a sectional — a three-cushion 2x4 frame sized to 24" cushions, designed to bolt to its neighbors.
| Part | Qty | T × W × L | Material | ✓ |
|---|---|---|---|---|
| Seat frame rails Sized to three 24" cushions — alter for yours. | 2 | 1 1/2" × 3 1/2" × 69" | 2x4 | ☐ |
| Seat cross members | 6 | 1 1/2" × 3 1/2" × 25 1/2" | 2x4 | ☐ |
| Leg pairs | 2 | 1 1/2" × 3 1/2" × 12 1/2" | 2x4 | ☐ |
| Back and seat planks | 6 | 1 1/2" × 3 1/2" × 72" | 2x4 | ☐ |
| Back rails | 2 | 1 1/2" × 3 1/2" × 69" | 2x4 | ☐ |
| Item | Qty | ✓ |
|---|---|---|
| 2x4, 12 ft Cut the 72" and 69" pieces from these — long stock wastes less against this list. | 6 each | ☐ |
| 2x4, 8 ft | 1 each | ☐ |
| Exterior screws, 2-1/2" to 3", self-tapping | 100 each | ☐ |
| Exterior wood glue | 8 oz | ☐ |
| Exterior stain Match the companion sofas. | 1 qt | ☐ |
| Outdoor cushions, 24" x 24" Three seat + three back. Not in the cost estimate; the frame is sized to them. | 6 each | ☐ |
Overall cost: $$. Lumber varies by region, species, and season, so we give a band rather than a figure.
Tools: Drill / Driver, Speed Square, Tape Measure. Materials: 2x4, 12 ft, 2x4, 8 ft, Exterior screws, 2-1/2" to 3", self-tapping, Exterior wood glue
Assemble the seat box — two long rails, six cross members — with exterior glue and screws (pocket holes work too if you prefer hidden joinery). Square it by measuring both diagonals and adjusting until they match exactly.
Six cross members for three cushions is deliberate: a seat frame member lands under each cushion edge, so no cushion ever bridges an unsupported span.
Tools: Drill / Driver, Tape Measure. Materials: 2x4, 12 ft, Exterior screws, 2-1/2" to 3", self-tapping, Exterior wood glue
Add the legs with the feet 28-1/2" apart — that number isn't arbitrary; it matches the companion sofa frames so the sectional's pieces sit at the same height and line. Glue and screws, two per joint minimum.
Tools: Drill / Driver. Materials: 2x4, 12 ft, Exterior screws, 2-1/2" to 3", self-tapping, Exterior wood glue
Screw the back planks to the tops of the back legs, then add the optional back support inset 1/4", screwed from the top and sides. The inset keeps the support's face behind the plane the back cushions rest on — it braces without printing a line into the cushions.
Tools: Drill / Driver, Random Orbit Sander. Materials: Exterior screws, 2-1/2" to 3", self-tapping, Exterior stain, Outdoor cushions, 24" x 24"
Sand, break the edges, and stain to match the rest of the sectional.
Then position it in the lineup and screw it to the adjacent sofa frames — the source calls this 'optimal support' and it's really structural necessity: armless pieces borrow their sideways stability from their neighbors. Cushions on, sectional complete, patio suddenly seats seven.