DIY corner unit for an outdoor sectional sofa

This DIY corner unit is a part of an outdoor sectional. If you are planning to make this outdoor sectional sofa, then read that post first.

I've explained there in a detailed tutorial how to make a one-armed sofa.

And here is a step-by-step how-to make a DIY ottoman for this sectional.

Instructions

STEP 1. Cut and assemble armrest of the corner unit

Cut two sides from 2x4s at 27 ½" long, one at 30 ½". And two boards from 2x4s at 20 ½" long. Make pocket holes screws using Kreg jig.

Attach 2x2x27 ½" under the armrest using screws and wood glue.

STEP 2. Cut and assemble shorter side

Before you start making this corner unit make sure you know what side you want this unit to be on. It would make a difference in assembly.

Follow the steps above and attach all parts together using Kreg jig pocket holes.

STEP 3. Attach both sides together

Cut two 2x4s at 20 ½" and attach sides using Kreg jig.

STEP 4. Add slats

Cut two 2x2" at 27" and attach them to the inner sides of the corner unit using wood glue and regular screws.

Cut slats for the seat support and attach it to the slat support.

For this step you can use any wood since it will be covered with a cushion. I used the wood I had left from the Montessori bed that I dissembled a year before when I built bunkbeds.

STEP 5. Attach the back

First, cut a 2x4" at 23 ½" and add it to the back of the chair using a Kreg jig. Make pocket holes from one side, so they aren't visible on the top. On another side, use 2 ½" wood screws and drive them from the top.

I know, the screws from the tops aren't glamorous, but if you use a bit of wood filler and sand it very well, they will be barely visible.

STEP 6. Cut and assemble back support

What makes this plan to stand out is that our sectional is so deep and comfy. To make it even comfier, I added a back support.

To make it cut two 2x3" at 13" and two 2x3" at 22" attach them with kreg jig. This right angled clamp is particularly helpful during assembly. Add a 17" board in the middle for extra comfort.

STEP 7. Finish this corner unit

For the finish I chose clear exterior sealer by Valspar. Use a bristle brush for easier application.

This lounge sectional sofa is so cozy and I'm looking forward to all the beautiful evenings we'll spend here with friends and family.

That's it for today!

I hope my explanation was decent and now you feel empowered that you can make the same!

xoxo,

April