Sep
02
2014
Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Project Details

If you liked the original Nova Sofa, but would love a bit more seating, this Sectional unit is just the ticket! Use the pieces from this collection either indoors or outside and it is equally as wonderful for both, perhaps just styled differently, no?

Showcase: Built From These PlansI am so honored each and every time one of you fine friends builds from these very plans! If you have built this piece, please take a moment and showcase your build! We are dying to see your fabulous hard work!

Estimated Cost
$150-$250
Dimensions
Dimensions for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Tools
Lumber
  • 16 – 1x2 at 8’ (It may be cheaper to buy 2 – 1x6 at 8’ then rip them into 1x2 strips on the table saw)
  • 4 – 1x3 at 8’
  • 1 – 1x8 at 6’
  • 1 – 1x10 at 6’
  • 4 – 2x2 at 8’
  • 2 – 2x6 at 8’
  • 1 – 2x8 at 8’
  • 1 sheet of ½” plywood
Materials
Cut List
  • 4 – 2x6 (ripped to 4-1/2” wide) at 22” – Legs
  • 1 – 2x6 (ripped to 4-1/2” wide) at 23-1/2” – Leg
  • 1 – 2x6 (ripped to 6” wide) at 14” – Leg
  • 1 – 2x2 at 49-1/2” – Back Stretcher
  • 6 – 2x2 at 12-1/2” – Support Legs
  • 2 – 2x2 at 43-1/2” – Inner Back & Front Stretchers
  • 1 – 2x8 (ripped to 6” wide) at 52-1/2” – Upper Back
  • 4 – 2x2 at 22-1/2” – Seat Supports
  • 1 – 2x2 at 8” – Inner Side Slat Support
  • 1 – ½” plywood at 25-1/2” x 49-1/2” - Seat
  • 1 – 2x6 (ripped to 4-1/2” wide) at 22-1/2” – Arm
  • 1 – 1x3 at 48-3/4” – Inner Back Slat
  • 3 – 1x2 at 50-1/4” – Inner Back Slats
  • 1 – 1x3 at 23-1/4” – Inner Side Slat
  • 3 – 1x2 at 23-1/4” – Inner Side Slats
  • 3 – 1x3 at 30” – Side Slats
  • 1 – 1x3 at 6” – Side Slat
  • 15 – 1x2 at 30” – Side Slats
  • 3 – 1x2 at 6” – Side Slats
  • 3 – 1x3 at 54” – Back & Front Slats
  • 1 – 1x3 at 6” – Front Slat
  • 15 – 1x2 at 54” – Back & Front Slats
  • 3 – 1x2 at 6” – Front Slats
  • 1 – 1x10 (ripped to 7-1/2” wide) at 54” – Back Trim
  • 1 – 1x8 (ripped to 6” wide) at 31-1/2” – Left Trim
Instructions

Before beginning to build, always check in on my site to make sure you have the most up to date set of plans, I occasionally update and change the plans to make the building process easier or to allow for less expensive purchasing of materials! Read through the entire set of instructions and all comments before beginning this project. If you print out or save plans, be sure to check in on my site to be sure you have the most up to date set of plans, as I occasionally update things for ease of building or buying. If you are new to building, read through the GETTING STARTED section and other articles found under the BUILD tab in the menu on my site, it has valuable information about how to get started, tools and techniques. If you are unfamiliar with the finishing process, visit my Finishing school for some tips and tricks for painting like a pro and for special finishing practices. Use glue to secure your joints and Consider Painting or Staining individual sections prior to assembling. This makes the paint application virtually flawless. Coat with a spray on Poly or Wipe on Poly to protect your finish and your piece and it will last for ages. Adhere to all safety standards and guidelines, and be sure you follow safety protocol throughout your build. If you are unsure about whether you are building safely, run a quick online search for the tool or technique you are using, or contact me via email or post to the forum before you move ahead. My contact info can be found in the menu of my site.

Step 1

Cut the pieces for two of the legs, two of the support legs, and the back stretcher. Set the Kreg jig for 1-1/2” material and drill pocket holes in each end of the stretcher, one end of the support legs, the top edge of the legs, and one long edge of the legs. (There will be a left and a right!) Assemble as shown using glue and 2-1/2” pocket hole screws.

Cut the pieces for the remaining two back legs and drill pocket holes in the top edge only. Attach the inner back legs to the outer back legs (in an L shape) using glue and 2-1/2” pocket hole screws.

Cut and Fasten Legs Supports and Stretchers using a Miter Saw and Kreg Jig for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Step 2

Cut the pieces for two of the legs, two of the support legs, inner back stretcher and the upper back. Drill pocket holes in each end of the stretcher and the top edge of the support legs, then attach as shown using glue and 2-1/2” pocket hole screws.

Attach the upper back piece to the legs using glue and 2-1/2” pocket hole screws.

Cut and Fasten Legs Supports and Stretcher using Miter Saw and Kreg Jig for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Step 3

Cut the pieces for the front legs, front support legs, and stretcher, and drill pocket holes in each end of the stretcher, one end of the support legs, and the top edge of the legs. Assemble as shown using glue and 2-1/2” pocket hole screws.

Cut and Attach Front Legs Supports and Stetcher using Wood Glue and Pocket Hole Screws for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Step 4

Cut the pieces for the seat supports and drill pocket holes in each end. Attach to the front and inner back stretchers using glue and 2-1/2” pocket hole screws.

Cut the pieces for the inner slat support and drill pocket holes in each end. Attach to the outer seat supports as shown using glue and 2-1/2” pocket hole screws. They will be positioned ¾” away from the inner back legs.

Cut and Attach Seat Supports using Wood Glue and Pocket Hole Screws for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Cut and Attach Inner Slat Support using Wood Glue and Pocket Hole Screws for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Step 5

Cut the piece for the seat. Cut the notches using a jigsaw, then secure to the seat supports using glue and 1-1/4” brad nails.

Cut and Notch Seat using Jig Saw for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Attach Seat using Wood Glue and Brad Nails for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Step 6

Cut the pieces for the arm and drill pocket holes at each end. Position as shown, then secure using glue and 2-1/2” pocket holes.

Cut and Fasten the Arm using Wood Glue and Pocket Hole Screws for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Step 7

Cut the pieces for the inner back slats. The 1x3 slat will be shorter than the 1x2 slats. Position the 1x3 slat between the inner back leg then secure in place using glue and 1-1/4” brad nails. The 1x2s will be positioned between the inner back leg and the inner side slat support. Position the 1x2 slats with ½” spacing between them then secure using glue and countersunk 2” screws through the support into the slats.

Cut and Attach Inner Back Slats using Wood Glue and Brad Nails for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Step 8

Cut the pieces for the inner side slats. Position as shown with ½” spacing between them, then secure using glue and 1-1/4” brad nails.

Cut and Attach Inner Side Slats using Wood Glue and Brad Nails for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Step 9

Cut the pieces for the outer side slats. Position as shown with ½” spacing between them, then secure using glue and 1-1/4” brad nails.

Cut and Attach Outer Side Slats using Wood Glue and Brad Nails for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Step 10

Cut the pieces for the outer back slats. Position as shown with ½” spacing between them, then secure using glue and 1-1/4” brad nails.

Cut the pieces for the front slats. Position as shown with ½” spacing between them, then secure using glue and 1-1/4” brad nails.

Cut and Attach Outer Back Slats using Glue and Brad Nails for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Cut and Attach Front Slats using Glue and Brad Nails for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Step 11

Cut the pieces for the trim. The angles on the trim are not pretty round numbers, but we can connect the dots to draw them. For the left side trim, measure 7-1/2” down from the outer top corner (your starting point) of the trim piece, make a mark, and draw a perpendicular line across the trim (the end of this line will be your ending point). Draw from your starting point to your ending point, and you will have your needed angle. Likewise for the top trim, measure 6” across from the top left corner (your starting point) of the trim piece, make a mark, and draw a perpendicular line across the trim (the end of this line will be your ending point). Draw from your starting point to your ending point, and you will have your needed angle.  For these angles to work, the chair needs to be square! Cut each a piece a little longer than the dimensions and play with the angles if necessary!

Cut and Fasten Trim for Free DIY Furniture Plans // How to Build a Nova Outdoor Sectional Sofa using Kreg Jig and Pocket Hole Screws with a Drill or a Nail Gun
Finishing Instructions

Fill any Screw, Nail or Pocket Holes, Sand and Finish as Desired. For Finishing Tips and Tricks visit my Finishing School

Outdoor 
Disclaimer

// Disclaimer: Some rights reserved. Private use only. Feel Free to link to any of my plans so long as you ONLY use 1 image and provide an ADEQUATE link back to the original source and appropriate plan! Plans from this page are not to be used for commercial purposes or republished without the express written consent of Rayan Turner, The Design Confidential I hope to provide accurate plans, however, I cannot guarantee each plan for accuracy. Not every plan that I post has been built and tested, so you are building at your own risk. It is recommended that you have a clear understanding of how the project works before beginning any project. Please contact me if you find an error or inaccuracy so that I might fix it. // Post May Contain Affiliate Links

Aug
30
2014
Reader Showcase // Two Toned Chaise Lounge for FFA Fair DIY Outdoor Kreg Jig Project Plans from Wood using Pocket Hole Screws

I found the plans for your chaise lounge chair and I started constructing it for my FFA fair, for a project that will be judged and showcased.

To Read More About This Build, Visit This Blog Post 
Estimated Cost 
Length of Time 
Modifications 
Lumber Used 
Finishing Technique 
Additional Project Details 
Reader Showcase // Two Toned Chaise Lounge for FFA Fair DIY Outdoor Kreg Jig Project Plans from Wood using Pocket Hole Screws
Note
Aug
25
2014
Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Project Details

Oh this piece of DIY Furniture might be one of my absolute faves! So utterly versatile and just the coolest... lay it flat to enjoy on your front side or snooze and when you feel like it, simply put it in one of several incline positions to lounge and chat! Isn't that amazing? Check out the images at the bottom to see how this gal moves and functions! Xx... Rayan

Showcase: Built From These PlansI am so honored each and every time one of you fine friends builds from these very plans! If you have built this piece, please take a moment and showcase your build! We are dying to see your fabulous hard work!

Estimated Cost
$75-$100
Dimensions
Dimensions for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Tools
Lumber
  • 5 – 1x4 at 8’
  • 5 – 1x3 at 8’
Materials
Cut List
  • 2 – 1x4 at 75”– Main Frame Sides
  • 2 – 1x4 at 29-1/2”– Main Frame Top and Bottom
  • 5 – 1x3 at 31” – Main Frame Slats
  • 2 – 1x4 at 19”– Middle Frame Sides
  • 2 – 1x4 at 26”– Middle Frame Top and Bottom
  • 2 – 1x4 at 2-1/2”– Middle Frame Spacers
  • 4 – 1x3 at 27-1/2”– Middle Frame Slats
  • 2 – 1x4 at 30-1/4”– Upper Frame Sides
  • 1 – 1x4 at 27-1/2”– Upper Frame Top
  • 5 – 1x3 at 29” – Upper Frame Slats 
Instructions

Before beginning to build, always check in on my site to make sure you have the most up to date set of plans, I occasionally update and change the plans to make the building process easier or to allow for less expensive purchasing of materials! Read through the entire set of instructions and all comments before beginning this project. If you print out or save plans, be sure to check in on my site to be sure you have the most up to date set of plans, as I occasionally update things for ease of building or buying. If you are new to building, read through the GETTING STARTED section and other articles found under the BUILD tab in the menu on my site, it has valuable information about how to get started, tools and techniques. If you are unfamiliar with the finishing process, visit my Finishing school for some tips and tricks for painting like a pro and for special finishing practices. Use glue to secure your joints and Consider Painting or Staining individual sections prior to assembling. This makes the paint application virtually flawless. Coat with a spray on Poly or Wipe on Poly to protect your finish and your piece and it will last for ages. Adhere to all safety standards and guidelines, and be sure you follow safety protocol throughout your build. If you are unsure about whether you are building safely, run a quick online search for the tool or technique you are using, or contact me via email or post to the forum before you move ahead. My contact info can be found in the menu of my site.

Step 1

Cut out the two Main Frame Sides. Drill a 1/2” hole 29” from one end of the Side and 1-3/4” from the top. Please note that all hole measurements will be TO the center of the hole. Drill another 1/2” hole 3” from the other end of the Side. Drill a series of 4 more holes in the same manner as shown, 3” on center and 1-3/4” from the top. You can drill more than 5 holes if you wish – this will give you even more adjustment opportunities! You will need to repeat this step twice – once for each Side. If you feel confident, clamp the Main Frame Sides together and drill both holes at once through the pieces.

Outside Frame Hole Placement for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Step 2

Cut out the Main Frame Top and Bottom and attach to the Main Frame Sides as shown with glue and pocket screws. 

Outside Frame for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Step 3

Cut out the Main Frame Slats and attach as shown using glue and 1-1/4” brad nails. Each Slat will be spaced 3” apart.

Main Frame Slats for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Step 4

Next, cut out the Middle Frame Sides. Drill a 1/2” hole positioned 1-1/2” from each end and 1-3/4” from the top. You will need to repeat this step twice – once for each Side. Or you can clamp the Middle Frame Sides together and drill both holes at once through the pieces.

Mid Frame Sides for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Step 5

Cut and attach the Middle Frame Top and Bottom to the Middle Frame Sides as shown with glue and pocket screws. 

Middle Frame for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Step 6

Next, cut the Middle Frame Spacers. Drill a 1/2” hole positioned 1-1/2” from the end and 1-3/4” from the top. You will need to repeat this step twice – once for each Spacer. Or you can clamp the Spacers together and drill both holes at once through the pieces. Align Spacers with the Sides so that the drilled holes match up and the edges are flush. Attach Spacers to the Middle Frame Sides as shown using glue and 1-1/4” pocket hole screws. 

Mid Frame Spacers for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Step 7

Cut out the Middle Frame Slats and attach as shown using glue and 1-1/4” brad nails. Each Slat will be spaced 3” apart.

Mid Frame Slats for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Step 8

On to the last portion of the Futon! Cut the pieces for the Upper Frame Sides. Drill two 1/2” holes – one positioned 1-3/4” from one end, and the other 1-1/4” from the other end, both 1-3/4” from the top. You will need to repeat this step twice – once for each Side. Or you can clamp the Sides together and drill both holes at once through both pieces.

Upper Frame Sides for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Step 9

Next, cut the Upper Frame Top and secure to the Upper Frame Sides as shown using glue and 1-1/4” pocket hole screws.

Upper Frame Top for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Step 10

Cut out the Upper Frame Slats and attach as shown using glue and 1-1/4” brad nails. Each Slat will be spaced 3” apart.

Upper Frame Slats for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Step 11

This is where the piece really starts to take shape! Lay out the Main Frame on a flat surface. Place the Middle Frame and Upper Frame within the Main Frame as shown. Attach the Upper Frame to the Middle Frame by aligning the drilled holes and inserting the (2) 2” clevis pins and hitch pin clips on both sides. Attach the Middle Frame to the Main Frame by aligning the drilled holes and inserting the (2) 3” clevis pins and hitch pin clips on both sides. Use the (2) 2” clevis pins and hitch pin clips to secure the Upper Frame to the Main Frame in the desired adjustment holes. Add a cushion for extra comfort! After finishing, you might find it helpful to apply a coat of paste wax to the areas of the Futon that pivot and rub against each other. Large washers may also be used for extra reinforcement at the end of the clevis pins. Lastly, use a sander on edges if you want a more rounded, softer appearance. 

Clevis Pin Assembly for Free DIY Furniture Plans // How to Build an Indoor Outdoor Single Futon Chaise Lounge
Step 12

Check out how versatile this piece is! It can lay flat or incline to several positions. We’ve included a few more graphics for you to see this Futon in motion.

Finishing Instructions

Fill any Screw, Nail or Pocket Holes, Sand and Finish as Desired. For Finishing Tips and Tricks visit my Finishing School

Outdoor 
Disclaimer

// Disclaimer: Some rights reserved. Private use only. Feel Free to link to any of my plans so long as you ONLY use 1 image and provide an ADEQUATE link back to the original source and appropriate plan! Plans from this page are not to be used for commercial purposes or republished without the express written consent of Rayan Turner, The Design Confidential I hope to provide accurate plans, however, I cannot guarantee each plan for accuracy. Not every plan that I post has been built and tested, so you are building at your own risk. It is recommended that you have a clear understanding of how the project works before beginning any project. Please contact me if you find an error or inaccuracy so that I might fix it. // Post May Contain Affiliate Links

Aug
24
2014
Reader Showcase // Emerson Queen Size Bed

Thank you TDC - My wife and I were able to build a beautiful bed and feel good about not spending $2K! The directions were easy to follow, and the result came out amazing. 

Modifications 

We made a few modifications to the plans - Replacing the plywood headboard with stained pine barn door slats and replacing wood clete with a metal bracket to hold lower support.

Reclaimed Lumber for Reader Showcase // Emerson Queen Size Bed
Finished Build for Reader Showcase // Emerson Queen Size Bed
Close Up and Finish for Reader Showcase // Emerson Queen Size Bed
Aug
19
2014
Reader Showcase // Hendrix Large Desk

My second build from TDC!

Aug
19
2014
Reader Showcase // Our Crate & Barrel Outdoor Furniture

My husband & I built these 3 pieces, plus a gorgeous table over the week-end....we used Fir lumber and stained them a warm red.....they are exactly what we had wanted and we didn't have to spend the 1100.00 to purchase them.......Thank you TDC for sharing the plans, it was so easy to build with your very descriptive examples.

Blessings,

Michelle

Lumber Used 

Fir lumber 

Finishing Technique 

Stained Red

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