Padded Headrest

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1 Cut the headrest back board to size, and mark the radius of all four corners using a compass set at 2in (51mm). Cut these with a coping saw and smooth the edges with glasspaper.

2 Cut the thick plastic foam to the same size and shape as the board and stick the two together with impact adhesive. (Ensure

FIG 10.9

Cutting the slots with a panel saw.

FIG 10.9

Cutting the slots with a panel saw.

Button

FIG 10.10

Section through padded headrest.

Fabric

Thin plastic foam

Thick plastic foam

Button

FIG 10.10

Section through padded headrest.

Fabric

Thin plastic foam

Thick plastic foam

FIG 10.11

Threading an upholstery button through the headrest.

FIG 10.11

Threading an upholstery button through the headrest.

that the foam is fire retardant - it is safer and also mandatory in some circumstances.)

This type of foam is available from specialist dealers and is easily cut with a sharp carving knife, using a piece of wood as a straight edge. Should you be unable to purchase a long enough piece, simply coat the two edges to be joined with impact adhesive and allow it to dry before pushing them together.

3 Place the second piece of thin fire-retardant plastic foam on the floor and position the foam-covered board on top of it, with the foam side downward. Coat the edges of the thin foam that show underneath the padded board, and the edges of the padded board, with glue. When the glue has dried, pull the thin foam around the padded board to form a smooth, rounded shape. Trim off any overhanging foam with a sharp knife.

4 My padded headboard is covered with a plastic vinyl fabric, although other fabric, perhaps to match the curtains, would also be suitable. Lay the fabric on the floor and pull it around the board in the same way as when covering the board with thin foam. Secure the fabric with upholstery tacks fixed into the back of the plywood board.

5 Mark the positions for the buttons on the back of the plywood board. At each mark drill two ^in (6mm) holes through the board, about '/2in (12mm) apart. Remove some of the wood between the holes with a bevel-edged chisel, so that the knot of the cord which holds the buttons will settle below the surface. This ensures that the padded board sits flush into the back board when screwed into place.

6 I used upholstery buttons covered in the same fabric as the headrest. These can be obtained from and covered by most upholsterers. They have a metal ring in the back through which a length of cord is passed. To attach the buttons to the board, push a length of wire right through one hole, the foam and the covering fabric in turn. Bend over the end of the wire to form a loop, thread the cord through the loop and pull the wire back through the cushion to the back of the board. Thread a button on to the cord and pull the second end through. Pull the cord tight and knot it: this has the effect of pulling the button into the cushion to create the 'dimpled' effect. Repeat for each button.

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