An outdoor sectional is the perfect way to create an inviting lounge area in your backyard, patio, or deck. Not only does it provide ample seating for family and friends to gather together, but it can also add style and personality to your outdoor space. While pre-made outdoor sectionals can be quite expensive, you can save money by making your own DIY version using basic construction skills and a little elbow grease.
Making your own outdoor sectional is a fun weekend project that will allow you to customize the size, shape, and look to perfectly suit your space and style preferences. Though it requires some effort, the right materials, and a helping hand, in the end you will have a one-of-a-kind outdoor sectional to enjoy for years to come.
Choosing the Right Materials
When it comes to materials for a DIY outdoor sectional, you want pieces that are weather and rust resistant, durable, yet still lightweight enough to move around your patio. Here are some of the best options to consider:
Aluminum: Aluminum framing is lightweight, rust-resistant, and can support the structure of a sectional frame. Look for square aluminum tubes or bars typically 1-2 inches thick for the frame. These can be cut to size and pieced together.
Steel: Powder coated steel is another good framing option for added durability. Though slightly heavier than aluminum, steel holds up well outdoors.
PVC Board: For a budget-friendly choice, use PVC panels for the framing and as the base for cushions. PVC is weatherproof, sturdy, and can easily be cut or drilled into. 3⁄4 inch thickness is recommended.
Cedar Wood: For a natural look, red cedar boards work beautifully for a DIY sectional. Cedar resists weathering, rot, and insects. Go for 1×4 or 1×6 boards.
Outdoor Fabric: When choosing fabric for DIY cushions, look for outdoor-rated, water-resistant fabric in acrylic, polyester, or olefin. Solid colors or colorful patterns both work well.
Outdoor Foam: High-density foam should be used for the cushions, ideally with a thickness of 4-6 inches for comfort. Look for foam designed specifically for outdoor use.
Fasteners: Stainless steel hardware like bolts, nuts, washers, and corner braces provide durability. Outdoor-rated wood screws also work for a cedar frame.
Paint/Finish: For wood, an outdoor semi-transparent stain enhances natural grain while protecting the cedar. Aluminum or steel framing can be spray painted any color.
Tools You Will Need
Before embarking on the building process, make sure you have the proper tools on hand to construct your DIY outdoor sectional:
- Power drill and drill bits
- Circular saw or miter saw
- Level
- Tape measure and ruler
- Squaring tool or carpenter square
- Pencil
- Safety goggles and work gloves
- Clamps
- Wrench or socket set
- Sandpaper
- Foam brush for staining
- Heavy duty staple gun and staples
- Scissors or utility knife
Having these tools ready will make building your own sectional much easier. You may also want an extra pair of hands to help with some steps.
How to Build the Sectional Frame
The frame is the foundation for your DIY outdoor sectional. This supports the weight and allows you to attach the cushions. Follow these instructions to build a strong, square frame:
1. Plan the Size
- Decide on dimensions for each section of the sectional – for example, two 30 inch by 72 inch rectangular sections and a 30 inch by 30 inch square corner piece.
- Sketch out the frame pieces needed and how they will fit together based on your total size.
- Account for the thickness of the cushioning when planning – aim for cushions around 5-6 inches thick.
2. Cut the Framing Pieces
- Using your measurements, cut the framing lumber, aluminum or steel into the required lengths using a miter or circular saw.
- Cut identical lengths for matching sides to keep the frame symmetrical.
- For wood, cut the boards to size with cross brace supports around every 18-24 inches.
3. Join the Framing Pieces
- Lay out the connected framing pieces of your planned sectional on a flat surface and ensure they join properly at 90 degree angles.
- Drill pilot holes and use either nuts/bolts or wood screws to construct each frame segment. Check for square angles with a level or square tool.
- Attach corner braces on the inside corners for added stability if desired.
4. Add Legs and Support
- For elevated seating, attach legs to the underside of the frame. Flush mount stainless steel legs work well for a clean look.
- Alternatively, place heavy duty deck blocks beneath the corners and middle of the frame for ground-level seating.
- Ensure the frame is level and sturdy enough to hold weight by testing the balance. Add cross supports beneath if needed.
How to Make Custom Outdoor Cushions
Once you build the frames, the next key step is creating cushions tailored to fit each section perfectly. Here are some easy methods for DIY outdoor cushions:
1. Make a Cushion Template
- Start by cutting a piece of cardboard the exact dimensions of the top of your sectional frame. This will serve as the template.
- Trace the template onto the foam and fabric to cut matching cushion pieces. Add a few extra inches to the fabric for wrapping the edges.
2. Cut and Shape the Foam
- Use an electric knife or serrated blade to cut the outdoor foam to size based on your template tracing.
- Cut identical pieces of foam for each sectional component. Angle the foam on the corners or curves.
- If desired, taper the front edge of the foam slightly so that cushions are thinner in front and thicker in back for reclining.
3. Prepare the Fabric
- Lay the outdoor fabric pattern side down. Center the matching foam on top.
- Pull fabric edges up over the sides and staple temporarily to hold in place while working.
4. Wrap and Attach the Fabric
- Start on one edge and pull the fabric tight around the foam. Use a heavy duty staple gun to permanently adhere it underneath.
- Work your way around the entire cushion, rechecking measurements to keep it even.
- Use a strong adhesive like contact cement for the final edge to close the seam and create a clean finish.
- Finish by attaching zippers or Velcro strips to join cushion sections.
Advanced Framing and Cushion Options
There are many creative ways to construct your DIY outdoor sectional to achieve different looks and functions. Consider these optional approaches:
Curved shape: Use bendable wood, steam to curve cedar boards, or cut angles into straight wood to create curves. Cut wedge-shaped foam cushions to follow shape.
Modular design: Keep sofa sections separate for rearrangement. Use corner hardware connectors to link frames.
Contour cushions: Sculpt foam with deeper reliefs for an ergonomic profile. Add lumbar support sections.
Sunbathing cushions: Attach a flat wooden platform to rear of frame. Cover with hinged foam and fabric cushion for laying flat.
Integrated storage: Add waterproof storage compartments underneath for blankets, pillows, etc. Use plastic boxes or upholstered crates.
Removable covers: Make fabric covers separate from foam forms. Secure with zippers or snaps for cleaning.
Ottomans: Build smaller cube frames, upholster with cushion foam and casters for movable ottomans to use as footrests or extra seating.
Finishing Touches
Add some final touches to complete your DIY outdoor sectional furniture:
- Sand any rough edges on wood framing and apply protective outdoor wood stain.
- Paint or spray paint metal framing in desired colors to match your style.
- Add throw pillows, cushions, blankets, and outdoor area rugs for added comfort.
- Incorporate small side tables for holding drinks, books, or serving snacks.
- string lights, lanterns, and potted plants are great ideas for enhancing the ambiance around the seating area.
- Protect your sectional with weather resistant furniture covers when not in use.
Putting in the time to build your own sectional gives you a custom furniture piece tailored exactly to your patio space and design taste. Just grab a cool beverage, sink into your comfy new sofa, and enjoy the outdoors in style!
Frequently Asked Questions
What is the easiest way to build a DIY outdoor sectional?
The easiest route for beginners is using pre-cut cedar boards screwed together for a basic box frame, with rectangular foam cushions covered in outdoor fabric stapled on top. This creates a simple yet attractive sectional with minimal cutting.
How do I figure out the dimensions of my DIY outdoor sectional?
First measure the space where you want to place the sectional, accounting for pathways. Sketch ideas and play with different shapes and sizes using graph paper. Standard depth is about 30-36 inches, but dimensions are flexible based on your needs.
Should I make cushions removable for my outdoor sectional?
Yes, removable cushion covers make cleaning, maintenance, and off-season storage much easier. Use zippers or Velcro to keep covers securely in place when used, but easy to remove as needed.
What is the best way to join wood boards for an outdoor sectional frame?
Using outdoor-rated wood screws and corner braces provides a sturdy way to construct a sectional frame from cedar boards while still keeping it easy to disassemble if ever needed.
How thick should the foam cushions be for an outdoor sectional?
A foam thickness between 4-6 inches provides optimal comfort and support for outdoor sectional cushions. This allows cushions to compress slightly under weight but still retain their shape and performance over time.
Can I use regular indoor foam for an outdoor sectional?
No, cushion foam meant for indoor use will break down quickly when exposed to weather and moisture outdoors. Use high-density foam specifically designed for outdoor furniture to have durable, long-lasting cushions.
What is the best fabric for DIY outdoor sectional cushions?
Look for water-resistant and fade-resistant outdoor fabrics like solution-dyed acrylics, treated polyester, or weather-resistant canvas. Avoid regular cotton since it absorbs moisture and mildews outdoors.
How do I add legs to my DIY outdoor sectional?
Flush mount stainless steel legs screwed into the frame work well. For stability, ensure legs are no more than 2 feet apart. For low, ground-level seating, place deck blocks under the frame corners instead of legs.
Should I varnish or stain my DIY outdoor sectional wood?
Staining or sealing outdoor wood is highly recommended since it protects against weathering, rot, and insect damage. Use a specially formulated outdoor wood stain for optimal protection on cedar or teak wood.
Conclusion
Creating your own DIY outdoor sectional may involve some work, but the reward is having a custom-made sectional that fits your space perfectly and suits your style. The right plans, materials, tools, and techniques will allow you to construct durable sectional framing, sculpt comfortable cushions, and add your own finishing touches. Once complete, you’ll have a wonderful place to lounge outdoors with family and friends for years to come. Be sure to care for your sectional properly when not in use and thoroughly enjoy the fruits of your furniture building labor.