Making a Headboard
In this picture we have glued boards together. The steps we took were to join the edges of the boards so that they would lay together without gaps. Then we applied wood glue and clamped the boards together with pipe clamps being sure to align the boards carefully. We allowed this part to set 24 hours before additional milling.
Using a jigsaw, cut out the pattern for your headboard. It is important to have the notch at the end of the pattern to be 1 3/8 deep and the top (app ½ tall) to tilt slightly towards the post as it intersects the post where it is tapered.
In this picture we see the bottom of the headboard. From the edge the corners need to be routed with a 3/8 round over bit on both sides. This is done so that the bottom of the headboard will fit snugly into the curve of the post mortise. One variation that you may consider is routing the front and back of the top and bottom of the headboard being careful to stop at the top notch and end of the bottom. In picture additional routing has been done with a ¼ round over bit.
Once the headboard has been cut, notched and routed the next step is to attach two battens to the back of the headboard. Often these are made from ¾ material and attached with #8 1 ¼\"screws.
Note that the notch near the post and at the top has not been routed. The bottom of the notch should fit snugly to the beginning of the curve at the top of the mortise.
Post inserted with snug fit.
Before screwing the headboard to the post you need to be certain of three things. 1. The post set on the table with the hardware mortise facing down. 2. The headboard is inserted into the post in such a way that that the batons are facing up. 3. The angle of the screws is to be such that it will not present itself out of the chamfer of the post on the front side. A good size screw to use for this project it #8 1 ¼\" screw. The footboard is attached to the posts with one thing different. 1. The post set on the table with the hardware mortise facing UP. 2. The footboard is inserted into the post in such a way that that the worse side is up. 3. The angle of the screws is to be such that it will not present itself out of the side of the post on the front side.
On the back of the headboard, screw into the post.
Put the screws in at such an angle that they don\'t come out the other side.
This is how it should look when you are done.
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