Published at Sunday, September 16th 2018. by Concepcion Kelley in Sectional Sofa.
I let the glue fully cure before removing the clamps and starting to assemble the next beam. I cut some 1 foot by 30-inch pieces of plywood which are going to serve as the top of the two side tables that are built into either side of the sofa. I used some long clamps to hold pieces of the frame in place. While I glued and screwed the layers together now, I was just kind of figuring out this design on the fly. So I just was grabbing random pieces to sort of instill in the panels, but I've since revised the drawings and when I posted on my website you'll see a more efficient design.
I raised everything up onto blocks so that they get underneath the pieces of the frame and glue and clamp them all securely together, while the glue on the frame was curing. I started to glue together pieces of 3-inch wide plywood strips that are going to serve as the 2 legs for the sofa. I used my orbital sander to sand the edges of the frame flush. I flipped the frame upside down and then started to attach the legs. I did this about 2 to 3 layers of plywood at a time gluing and screwing between the layers.
After securing the first three layers of the legs in place and glued and screwed some spacers and a beam, that's going to go underneath the seat and backrest of the sofa. This beam is just made out of two layers of the 3 inches wide by wood strips. What's cool about this design is that you can make this sofa as high or as low as you want. Simply by adding more strips of plywood to the legs I use my circular saw to rip a thin strip of plywood at a 45-degree angle.
This is going to serve to fill in the gap between the seat board and the frame. I glue this filler piece flush to the front of the frame sanded down the angle of the filler piece so that the seat board would fit in nice and tight. I screwed the seat board in place and then test fit the back piece. I marked the angle of the back piece on a 3-inch wide strip of plywood and then cut a triangular shape out of it after cutting a bunch more triangles the same size.
I glue these pieces together to make supports for the backrest and maybe supports five and six layers thick and then stand-down all the edges. With my orbital sander and sanded the seat board flushes to the front of the frame. I then placed a backrest and then glued and screwed. The triangular supports to the backrest I didn't screw.
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