Solid Pine Box-Frame Two-Seater Outdoor Couch
by Nikos Papadopoulos
Build a 1600 mm wide box-frame outdoor couch from solid pine, with a slatted seat base, slatted back and chunky charcoal-grey weatherproof cushions. It suits anyone with a garden terrace, basic power tools and one free weekend — every joint is screwed, so no woodworking joinery is required.
Wood
Pine post timber 70 x 70 mm
2 lengths of 2.4 m, planed pressure-treated or knot-free pine (cut into the 4 corner posts)
27
Pine rail timber 45 x 95 mm
4 lengths of 2.4 m (become the seat rails, arm rails, back top rail and centre support beam)
36
Pine slat timber 20 x 95 mm
6 lengths of 2.4 m (become the 12 seat slats and 3 back slats)
33
Pine board 25 x 110 mm
1 length of 1.8 m planed board (becomes the two arm cap boards)
14
Hardware
Stainless steel screws 6.0 x 100 mm
Box of 100, A2 stainless countersunk (all main frame joints, 2 per joint)
25
Stainless steel screws 4.0 x 40 mm
Box of 100, A2 stainless countersunk (fixing seat slats, back slats and arm caps)
14
Stainless corner brackets 50 mm
8 brackets with matching 4 x 20 mm screws (hidden reinforcement inside the seat rail corners)
12
Pine wood plugs 10 mm
Bag of 50, 10 mm diameter (fill the counterbored screw holes on show faces)
7
Plastic furniture glides 25 mm
4 nail-in or screw-in glides (lift post ends off wet paving)
8
Waterproof exterior wood glue
250 ml D4-rated PVA (glue for the wood plugs only)
8
Finishing
Clear satin exterior decking oil
1 L UV-resistant oil (two coats over the whole couch)
22
Abrasive paper 80 / 120 / 180 grit
3 sheets or discs of each grit (rough shaping through to final smoothing)
10
Charcoal-grey outdoor seat cushion
1 cushion 1450 x 700 x 100 mm, water-repellent olefin or acrylic cover with quick-dry foam core
110
Charcoal-grey outdoor back cushions
2 cushions 700 x 400 x 120 mm, same weatherproof fabric (backrest)
70
Step 1 of 7
Cut list — every piece before you assemble anything
MATERIALS
TOOLS
Mitre saw→ 90° crosscut stop
Tape measure
Combination square
Trestles or workbench
CUT ALL PINE PIECES
- ✓Mark all lengths before cutting
- ✓Cut identical pieces in single batch
- ✓Label each piece with chalk after cutting
Instructions
PHASE 1 FRAME, from 70 x 70 mm pine: 2x front posts 600 mm, 2x back posts 780 mm. From 45 x 95 mm pine: 2x long seat rails 1460 mm (front + back), 2x side seat rails 640 mm, 1x centre support beam 1510 mm, 2x arm rails 640 mm, 1x back top rail 1460 mm. PHASE 2 CLADDING, from 20 x 95 mm pine: 12x seat slats 780 mm, 3x back slats 1460 mm. From 25 x 110 mm board: 2x arm caps 710 mm. Cut every piece square on the mitre saw, label each on the end grain in pencil, stack by group. Safety: wear safety glasses and hearing protection at the mitre saw; support long boards on trestles so they cannot tip mid-cut.
Time & Waiting
Active work
1-1.5 hours
People
1 person
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