- 2’x4’ 3/4″ Oak Plywood
- 1/4-in. Pine Dowel
- Wood Glue
- 2-in. 18-Gauge Brad Nails
- 3/4″ Oak Iron-On Edge Banding Veneer
- Miter Saw
- Table Saw/Circular Saw
- 18-Gauge Brad Nail Gun
- Hand Saw
Measure your sofa arm
Measure from the top of the arm to midway through the sofa cushion. This is the length of the sides (B). Ours was 10-in. Clamp two straight edges along the sides of the arm and measure the distance in between them. Add 1-1/2 in. to your measurement for the final length of the top (A).
Cut the parts to size
Rip the plywood to 10-in.-wide strips. Cut parts A & B to length according to the dimensions you found in Step 1. Crosscut the remaining parts (C & D) to length as shown in the cutting list.
Cut the phone groove
Set up your dado set for a 1/2-in. x 1/2-in. cut., 2 in. from the fence. Cut the phone groove along the length of the top (A). You could use a router for this if you prefer.
Apply edge banding
Rough cut the edge banding. Iron the edge banding so that the edges overhang both faces of the plywood. Rub the edge banding down with a wood block while the glue is setting, to ensure good adhesion. With the edge banding face-down on your bench, carefully trim the excess with a utility knife. Don’t apply edge banding on edges that butt into other parts.
Glue and pin
Glue the ends for the butt joints. Pin the boards together with 2-in. brads. Make sure to locate the nails so that they won’t interfere with the dowels.
Drill dowel holes
Mark three spots along each joint at 1-in. 5-in. and 9-in., 3/8-in. from the edge of the board. A painter’s tape flag on the drill bit 1-1/2 in. from the end of the bit tells you how deep to drill.
Install the dowels
Insert the dowel rod into the holes and mark it’s length, about 1/16-in. proud of the hole. Cut the dowels to length. Spread a little glue on each dowel and press them into their holes. Wipe off any excess glue. When the glue is dry, sand the dowels flush.