Making a sofa can be a fun and challenging experience. A new sofa can be very expensive, especially if it is a name brand. Making a modern sofa can be rewarding but will require the proper materials and skills to ensure that the sofa turns out correctly.
Purchase five pieces of multilayer plywood. Choose the size of the wood based on the size you wish to build your sofa. Measure the area where the sofa will be in order to get an accurate number. Write down the measurements and take them with you when you purchase the lumber. If unsure of size, get 43 x 47 inch boards.
Modern sofas come in different shapes, but making a square shape sofa may be easiest because the wood can be attached at the corners. After you’ve selected your shape, draw it on a large piece of paper. This will serve as a blueprint for your sofa. Cut out the design after it is drawn.
Place the cut out piece of paper onto the first wooden board. Make sure the wood is on a flat, steady work table. Take an electric saw and cut the shape around the paper into the wood, so that the wood takes the shape of the design.
Take the second plywood board, and cut it in three, long sections. Attach plywood to the center of the wood you previously cut, by using L-shaped metal bars. Form a box shape on top of the base wood, by attaching all three corners. Leave one end open, near the edge of the bottom piece of wood. Use the metal bars to hold attached pieces at each top corner, and to attach wood to base.
Add the third piece of wood as the top layer, over the box shape. Attach using screws and for extra strength, you can attach wood to the legs through the L-shaped metal bars.
Use the fourth piece of wood to hide the inner support of sofa, and to form the front of the sofa. Cut wood into the same shape and size of the sofa. Attach wood using screws. Cut the wood and fit it by measuring sections along the sofa for an exact fit, so that the wood doesn’t splinter while being fitted to the shape of the sofa. Use the fifth piece of wood for the back and sides, and repeat steps.
Re-use the paper shape, and cut out both high and low density foam in the shape of the paper. Use low density foam on top, for softness. Glue the foam parts together, then onto the surface of the wood with foam glue, and let dry overnight. Add upholstery material in fabric pattern of your choice, and stretch over sofa, stapling in place as you go along. Start at the back of the sofa, and pull the fabric tight while stapling, so it doesn’t bunch in sections. Bring over to the front, and continue. Cut away excess fabric with an upholstery scissor, and staple remaining fabric in place. Things You’ll Need
- Five pieces of plywood
- Electric screwdriver
- Electric saw
- Metal bars to connect wood pieces
- Large sheet of paper
- High density Foam (10 cm)
- Low density Foam (3 cm)
- Staple gun
- Foam glue
- Multiple yards of upholstery fabric
- Upholstery scissors