Woodworking plan · No. 62

2x4 Outdoor Sofa

A three-seat outdoor sofa built from 2x4s and one sheet of exterior plywood, sized for three 24″ × 24″ cushions. Slatted arms, a straight back for back cushions, and drain holes in the seat.

Skill
Level 3 of 5 · Intermediate
Build time
7 to 9 hours, plus finish
Lumber
11 2x4s and 1 sheet of ¾″ plywood
Joinery
Structural screws and deck screws
Finished size
78″ L × 31″ D × 28″ H
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What you need

Lumber sizes

A 2x4 is actually 1½″ × 3½″. Every measurement in this plan uses the real size. ¾″ plywood is drawn at full thickness, but plywood sold that way is often a hair thinner, so measure yours and cut the pieces that fit between panels to match.

Shopping list

  • 112x4, 8 ftPressure-treated or cedar.
  • 1¾″ plywood, 4 × 8 ft sheetExterior grade. The seat deck.
  • ~403″ structural wood screws, exteriorSuch as GRK or Spax, for the frame and legs.
  • ~903″ exterior deck screws
  • ~102½″ exterior deck screws
  • ~301⅝″ exterior deck screws
  • 3Seat cushions, 24″ × 24″Plus back cushions.
  • 1Exterior paint or stain

Tools

  • Miter saw or circular saw
  • Drill/driverWith a ½″ bit for the drain holes.
  • Level
  • Tape measure, speed square, pencil

Links for the hardware and tools ↓

Cut list

Twenty-eight pieces from eleven boards and one sheet. Label each piece with its letter in pencil as you cut it.

PartQtySize, inchesFrom
ABack posts41½ × 3½ × 282x4
BFront posts21½ × 3½ × 23½2x4
CEnd cross pieces21½ × 3½ × 312x4
DFront and back rails21½ × 3½ × 692x4
EMiddle cross pieces21½ × 3½ × 24½2x4
FMiddle front legs21½ × 3½ × 12¾2x4
GSeat deckSix ½″ drain holes.1¾ × 27½ × 72¾″ plywood
HBack boards31½ × 3½ × 752x4
IArm slats81½ × 3½ × 312x4
JArm caps21½ × 3½ × 262x4

Board layout. Each row is one board, cut left to right, with the remainder hatched. Dark lines are saw cuts, about ⅛″ wide.

Hardware & tools

Everything besides the lumber, with a link for each.

Links go to Amazon. Woodable earns a small commission at no cost to you.

Hardware

Fasteners

  • 3″ structural wood screws, exteriorSuch as GRK or Spax, for the frame and legs.~40View on Amazon
  • 3″ exterior deck screws#9 or #10 × 3″, coated or stainless, rated for outdoor use and treated lumber.~90View on Amazon
  • 2½″ exterior deck screws#9 or #10 × 2½″, coated or stainless, rated for outdoor use and treated lumber.~10View on Amazon
  • 1⅝″ exterior deck screws#9 or #10 × 1⅝″, coated or stainless, rated for outdoor use and treated lumber.~30View on Amazon

Glue & finish

Tools

Build it

Eight steps. The 3D view follows along as you scroll. The parts you're working on are yellow, and the pocket holes or screws for that step are red.

Step 1 of 8Cut the pieces
  1. 01

    Cut the pieces

    Measure your cushions first. This fits three 24″ × 24″ seat cushions between the arms, with room behind for back cushions. For other cushions, change the rails (D), back boards (H) and seat deck (G) by the same amount.

    • A Back posts, four at 28″
    • B Front posts, two at 23½″
    • C End cross pieces, two at 31″
    • D Front and back rails, two at 69″
    • E Middle cross pieces, two at 24½″
    • F Middle front legs, two at 12¾″
    • G Seat deck, one at 27½″ × 72″
    • H Back boards, three at 75″
    • I Arm slats, eight at 31″
    • J Arm caps, two at 26″

    Drill six ½″ drain holes through the seat deck (G) so rain can't pool under the cushions.

  2. 02

    Build the two arms

    For each arm, lay a back post (A) and a front post (B) on a flat floor, 31″ apart at the outside, bottoms lined up. Screw the four arm slats (I) across them with 3″ deck screws, two into each post: the lowest one 3½″ up from the bottom, the rest 2″ apart, the top one flush with the top of the front post.

    Build the second arm as a mirror image, so the slats end up on the outside of both arms.

  3. 03

    Build the seat frame

    Stand the front and back rails (D) on edge between the two end cross pieces (C): the front rail flush with the front ends, the back rail 3½″ in from the back ends. Drive two 3″ deck screws through each end cross piece into each rail.

    Fit the two middle cross pieces (E) between the rails, centered 27″ and 51″ from the left end, and screw through the rails into them.

  4. 04

    Join the arms to the frame

    Stand the arms up, slats out, and set the seat frame between them with its top 12¾″ above the floor. Drive four 3″ structural screws through each end cross piece into each arm post.

    Stand the two middle back posts (A) behind the back rail and the two middle front legs (F) behind the front rail, just outside the middle cross pieces. Drive two structural screws through the rails into each one, and two through the middle cross piece into each leg.

    Watch outEvery leg and post must stand on the floor before you screw it, so all eight share the load.
  5. 05

    Screw down the seat deck

    Lay the seat deck (G) on the frame between the arms, its back edge against the back posts. Screw it down with 1⅝″ deck screws every 8″ or so into the rails and cross pieces.

  6. 06

    Add the back

    Stand the first back board (H) on edge on the seat deck, against the front of the four back posts, and screw it to each post with two 3″ deck screws. Add the other two above it with 2″ gaps. The top one ends flush with the tops of the posts.

  7. 07

    Add the arm caps

    Lay an arm cap (J) flat on each arm, flush with the outside and the front, its back end against the back. Drive two 2½″ deck screws into the front post and two into the top arm slat.

  8. 08

    Finish

    Round over the front edges of the arm caps and every corner people touch, and sand smooth. Seal the plywood edges well, then paint or stain the whole piece with an exterior finish.

    TipUse outdoor cushions with quick-dry foam, and bring them in or tip them up after rain.

    Get this hardware: Outdoor seat cushions, 24″ × 24″

Build safely

Build at your own risk. Check every measurement against your own lumber before you cut, test-fit before you glue, and wear eye and ear protection. Full disclaimer.

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Plan No. 62