Headboard Frame

1 Cut the wood for the two upright posts to size and plane all faces square. Using a router with a 3/8in (10mm) core-box cutter, form the three ornamental flutes on the face of each post (see Fig 10.3) and then clean up with glasspaper wrapped around a piece of 3/sin (9mm) dowel (see Fig 10.4).

2 Cut the top and lower rails to length and mark the long, smooth curve on the top of the top rail. To draw this use a piece of flexible plywood about the same length as the rails. Hold it near the top of the rail, on its edge, and then bend it into the

63in (1,600mm)

45bln (1,156mm)

6in (152mm)

2in (51mm) radius

10in (254mm)

4in (102mm)

2in (51mm)

3in (76mm)

FIG 10.1

Plan of headboard with dimensions.

54in (1,372mm)

56in (1,422mm)

32bin (826mm)

24in (610mm)

Batten on back of headboard

6in (152mm)

FIG 10.3

Cutting the flutes with a router.

FIG 10.4

Smoothing the grooves with glasspaper.

Headboard Template

FIG 10.5

Headboard template.

FIG 10.6

Using a jig to make a dowelled joint.

Panel pin inserted at

Upright post required curve. Use a pencil to trace along its edge and mark the curve. This is a two-person job, one holding the plywood while the other draws around it. Draw the end shapes on the wood by squaring up from Fig 10.5.

3 When all the curves have been drawn, cut around them with a coping saw, or a band saw if available (which saves a lot of hard work), and smooth the shape with a rasp, file and glasspaper. Make the ends of both rails square by marking carefully with a try square before sawing.

4 Using a router with a bin (12mm) flat cutter, cut rebates from one end to the other in the back edges of both rails, and cut stopped rebates in the inside edge of the upright posts, to house the plywood back.

5 Join the rails to the upright posts with dowelled joints (see page 19), using a dowel jig to drill the holes (see Fig 10.6). Test the joints for accuracy and then glue hardwood dowels into the r*

upright posts.

6 Cut the wood for the two post caps to size and round off the fronts and sides with a plane. Fix the caps to the tops of the uprights with glue and pins. So that the heads of the pins do not show, punch them below the surface, fill the holes with pine-coloured filler and glasspaper smooth when dry.

7 Apply glue to the ends of the rails, then join them to the posts and clamp together.

FIG 10.5

Headboard template.

Plywood FIG 10.8

Method for inserting pins.

Upright post

FIG 10.6

Using a jig to make a dowelled joint.

Nin (25mm)

Side view of upright post

FIG 10.7

Dimensions for post caps.

Panel pin inserted at

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