Plans

Free DIY Furniture Plans to Build a Pottery Barn Inspired Chesapeake Corner Unit

06.21.12 By //
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That's right folks… we are going to be covering plans for the Chesapeake Sectional Sofa! Can I get a yahoo? Now go…build…make momma proud, and be sure to share pictures with us along the way! We LOVE a good Builders Showcase post!

Estimated Cost 

$50-$75

Dimensions 
Dimensions for This Project

Tools 
  • Tape Measure
  • Saw – Jig, Circular, or Miter
  • Drill
  • Square
  • Sander
  • Kreg Jig
  • Hammer or Brad nailer
Lumber 
  • 2 – 4×4 at 6’
  • 4 – 1×3 at 8’
  • 6 – 1×3 at 6’
  • 1 – 1×2 at 6’
Materials 
  • 1-1/4” pocket hole screws
  • 2” pocket hole screws
  • Small nails or 1-1/4” brads
  • Wood filler
  • Sandpaper
  • Wood glue
  • Finishing Supplies
Cut List 
  • 3 – 4×4 (ripped to 2-1/2” x 2-1/2”) at 33” – Side & Back Legs
  • 1 – 4×4 (ripped to 2-1/2” x 2-1/2”) at 13” – Front Leg
  • 12 – 1×3 at 29” – Aprons & Back Slats
  • 2 – 1×3 (ripped to 1-3/4”) at 29” – Seat Supports
  • 2 – 1×3 (ripped to 1-3/4”) at 32-1/2” – Seat Supports
  • 2 – 1×2 at 29” – Seat Slats
  • 9 – 1×3 at 32-1/2” – Seat 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

Step 1 

Cut the piece for the back leg. Rip the 4×4 on a table saw to 2-1/2” x 2-1/2. The easiest way to cut the angle in the piece would be to draw the lines on the lumber. Brace it and clamp it down so it can rest on the corner edge and carefully cut the line with a jigsaw. Then, with 60 grit sandpaper, sand the angle until it is smooth.

Step 2

Step 2 

Cut the pieces for the side legs. Rip them on a table saw to 2-1/2” x 2-1/2. Draw the angle on each board and cut with a jigsaw. Sand the angle.

Step 3

Step 3 

Cut the pieces for the aprons and the front leg. Set the Kreg jig for ¾” material and drill pocket holes in each end on the aprons. Secure to the legs as shown using glue and 2” pocket hole screws.

Step 4

Step 4 

Cut the pieces for the supports. Drill pocket holes in each end of the longer pieces. Attach to the aprons at the spacing indicated using glue and 1-1/4” pocket hole screws.

Attach the shorter pieces to the aprons using glue and 1-1/4” brad nails. (Countersunk screws can also be used.)

Step 5

Step 5 

Cut the pieces for the back slats. Drill pocket holes at each end. Secure to the legs flush with the angle using glue and 2” pocket hole screws. There will be a 1” space between each board.

Step 6

Cut the pieces for the seat slats. Attach the 1×2 slats using glue and 1-1/4” brad nails through the top of the slats into the center supports. Use a few brad nails through the front of the aprons into the side of the slats.

Set the first wider slat ½” from the 1×2 slat. Attach with glue and 1-1/4” brad nails through the top of the slat into all supports. The next slat (and all remaining slats) will be spaced ¾” apart.

Finishing Instructions 

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

**Disclaimer: Some rights reserved. Private use only. Feel Free to link to any of my plans so long as you provide an adequate link back to the appropriate post! 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.

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