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How to make a D.I.Y. modern timber sofa lounge

Lounge room with DIY modern timber sofa lounge.

Overview

Stylish, modern sofa lounges can be costly. This project repurposes three timber kitchen benchtops to create a fantastic piece of furniture that's perfect for just about any home.

Steps

1Cut the back and base or seat to size

Measure and mark on the tape the seat or base size. Ours measured 1920mm x 600mm. Measure and mark on the tape the size for the back of the sofa. Ours measured 1927mm x 420mm. Use the circular saw to cut these. Before cutting, be sure to allow for the blade.
Person using circular saw to cut piece of timber to length.

2Cut the rebates

Mark the tape on the timber, which is on the left and right side of the sofa. Also mark with a pencil where to cut the rebates. They need to be mirror images when you're done. Measure and mark the rebates – ours measured 25mm deep and 38mm from the edge for both sides and at a right angle. We used a table saw to cut the rebates for accuracy, but you could also use a circular saw.
Person placing two bits of timber together.

3Cut the sides and back to size

Next, measure and cut the sides and back with a circular saw. The sides measured 420mm, as did the back.
Person using circular saw to cut piece of timber to length.

4Cut the timber to a manageable size

To make working with the timber easier, we cut our benchtops to a more manageable size. We measured and marked ours at 680mm lengths and cut it with the drop saw.
Person using circular saw to cut piece of timber to length.

5Fit the base into place

Lift the base into place onto the created rebates, but you might need someone to help you lift it. To secure, glue, pre-drill with the 5mm bit, then make a pilot hole with the 3.5mm bit and join together with the 65mm timber screws.
Two people placing base of modern timber sofa lounge down.

6Fix the back and the sides together.

Clamp the sides to the back with corner clamps to keep the edges flush and square. To hide the screws, we're going to use timber plugs, which we'll make later. To accommodate these, pre-drill with a 9.5mm bit, then make a clearance hole with the 5mm bit. Apply glue for extra strength, removing any excess as you go. Make a pilot hole with the 3.5mm bit and then screw together with the 65mm timber screws.
Person placing side of timber sofa lounge against base.

7Make the square cuts

Now that the timber is at manageable lengths, it's time to make the square cuts. Start with the sides. Measure and mark where to apply the masking tape, the tape ensures the timber doesn't splinter when it's cut. Now measure and mark for the cut. Ours measured 638mm. We left some room to play with on the sides to accommodate any errors when cutting the rebates. Set the circular saw to make the cut, making sure you allow for the blade. Clamp the timber, then cut it. Repeat the process for the second side.
Person measuring piece of timber.

8Make the timber plugs

We're using an offcut of wood to make the timber plugs. First, set up the drill press with a plug cutter. Drill as many plugs as you need. Use a screwdriver to pop the plugs out. Now, align the plugs on top of the screws holes, making sure the timber grain faces the same way. Glue and gently hammer the plugs into place. If you don't have a drill press to make the plugs, you can just putty over the holes.
Person using plug cutter on bit of timber.

9Putty and sand

Putty up any gaps in between the timber joins and leave to dry. Use the belt sander to sand it. Start with 120-grit for the first sand and graduate to a finer grit as required.
Person puttying up gaps in wood and sanding it off.

10Make and assemble the legs

Our legs are a rectangle shape. Firstly, measure and mark them. Ours measured 580mm x 4 for the long sides and 152mm x 4 for the short sides. Cut them using a drop saw. Use 180-grit sandpaper to sand off any rough edges or branding. To make 1 leg, lay out the 2 longer sides parallel and fit the shorter sides between these. Assemble using butt joins. Measure and mark to drill a clearance hole with the 6.5mm bit, countersink, pilot hole with a 5mm bit. Glue and screw together with the 100mm bugle screws. Wipe away any excess glue. Putty and sand the leg. Repeat for the second leg.
Person drilling pieces of timber together to be used for timber sofa lounge arm rests.

11Attach the legs

Measure and mark for the legs. We positioned ours 35mm in from the front and 180mm in from the sides. Remember to stagger and skew your screws, so they don't touch, when attaching both legs to the sofa. Pre-drill a 6.5mm clearance hole and countersink for the depth. Then drill 5mm pilot holes before screwing the 65mm bugle screws into place.
Person drilling arm rests of timber lounge to the base panel.

12The finishing touches

To finish the sofa, apply a coat of clear varnish to protect the timber and bring out the natural grain. Before applying, wipe any dust off the sofa. Apply as many coats as needed, leaving them to dry in between.
Person varnishing piece of timber.

13Sit back and relax

Once the varnish is dry, move your lounge sofa into place. Accessorise it with some cushions, pillows and a throw rug for a touch of style. Your guests won't believe you made it yourself.
Finished modern sofa lounge.

Suggested products

Health & Safety

Asbestos, lead-based paints and copper chromium arsenic (CCA) treated timber are health hazards you need to look out for when renovating older homes. These substances can easily be disturbed when renovating and exposure to them can cause a range of life-threatening diseases and conditions including cancer. For information on the dangers of asbestos, lead-based paint and CCA treated timber and tips for dealing with these materials contact your local council's Environmental Health Officer or visit our Health & Safety page.

When following our advice in our D.I.Y. videos, make sure you use all equipment, including PPE, safely by following the manufacturer’s instructions. Check that the equipment is suitable for the task and that PPE fits properly. If you are unsure, hire an expert to do the job or talk to a Bunnings Team Member.