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BEDS


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ubsher: Jim Childs

Associate publisher Helen Abert

Associate editor Strother PurdyCopy editor Nancy . Bailey

Indexer Peter Chapman

Cover designer Steve Hughes

nterior designer Lori Wendin

Layout artists ori Wendin and Amy Bernard Russo

Front cover photographer Randy O'Rourke

Back cover photographer Tanya Tucka

Interior photographer Tanya Tucka, ecept where noted

Illusrator Bob a Pointe

Tet 1999 by eff Miller

Photographs 1999 by The aunon Press, nc

llustrations 999 by The Taunon Press, ncAll rights reserved.

Printed in the United States of America

0 9 8 7 6

The Taunton ress nc.,

63 South Main Street, PO Bo 5506 ewtown CT 06470-5506

e-mail tp@tauntoncom

Libary of ngress Cataloging-in-Publication Daailler Jeff 956

Beds outstanding projecs from one of America's best craftsmen /Jeff iller

p cm. (Step-by-step)

SB-3 9785658-254-9

SB0 -5658-549

Beds 2. urniture making 1. itle II Series Step-by-Step (Taunton Press)

TT97.5.B455 1999

6815dc21

ABOUT YOUR SAFETY

99-15009

CP

Working wt wood s nheently dageous. Usng and o powe toos mproperly o igog stadadsafey pacces can ead o perae juy or even deah. Don't ty to perfor ope atos you leaabou ee (o esewhee) uless youe certain hey are safe for you. I sometg abou an opeaodoesn fee rgh, do do t. Loo fo aoe way. We wa you to enoy he crat, so please eep safetyfoeos you md wheever youre woking wt wood.


7/196

To Becky, saac, and Arie

ACKNOWLEDGMENTS

A book ike this isn't writen without hep. Some of the help-a quick check of a fact

or the conrmation of the sanity of an idea-is casua, the stu of friendship. I

thank a of those whove assisted me in this way for heir suppor Other hep is

much more substantial Around the shop, Ive gotten hel p, support, and friendship

through both ordinary times and some rather extraordinary ones from Bruce Sharp,

Craig Kucina, Andy Brownell, Jason Holtz Bruce McDonald, and Tracy Perrio.

Tanya Tuckas wilingness to run over to photograph whatever was going on

making i look not ony easy but good as we-made the process ever so much

easier. I value the hep ve gotten from Strother Purdy, Helen Albert, and NancyBailey a Taunton, especially Strothers willingness to put up with my questions,

opinions, and ranings

A special thanks to Birgitte Wiliams, who allowed me to se up shop in her bas e

ment so many years ago, getting me started down this fascinating pah.

And I always carry with me the support of my parens, my wife, and my children.


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2 INTRO DUC TION

4 BD-BULD BAC

18 BD

36 AK-L BD

52 PCL-P BD

72 C BD

90 CAMA-L BD

112 D BD

130 PLAM BD

144 L BD

164 BUK BD

182 APPENDIX: Finishing Beds with Oil and Wax

183 SOURCS

184 METRIC CONVERSION CHART

185 INDEX


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2

W

spd clos to a thid of

ou livs i bd. Fo this

aso alo i a icasigly fast-

pacd ad slp-dpivd wold ou

bds a ou mos t impotat plac of

pos. But it is th oth activitisthat hlp mak ou bds so spcial.

W watch tlvisio. W ad stois

to ou child. W stay up too lat

ouslvs with a good book (a plasu

usually gttd th t day Ou

child us th bd as a tampoli.

W us th bd as a . tampoli d

w sv bakfast i bd as a vy

spcial tat.

Fo ths asos th bd is o of

th most sigicat pics of fuitu

i th hom akig with th diig

oom tabl as a majo puchas o poj-

ct. But wh th diig tabl is som-

thig of a showpic th bd has a

mo pivat maig. Ou choic of

bd vals mo o f ou imost

idas of pos comfot ad familylif. Physical comfot is ot th issu

thats up to th mattss. ts th bd

fam that matts I buildig o

choosig o its almost as if w c-

atig som sot of pivat shlt This

itimat shlt ca tak may foms

fom th pu ad simpl to th ich

ad imposig.

Whatv th bd looks lik

aust o laboatth basic stuc-

tu is faily simpl. h hadboad

ad footboad a gally spaat


11/196

pieces coected to the side ails with

some fom of kockdow joiey

Thee ae moe complex aiatios

but I haet foud much use fo them

Ie deeloped a quick easy ad ey

study coectio system based otaditioa bed bolts which I use o

most o f the pojects i th is book

This book ca be see as a collectio

of good bed pojects that utiize this

simple system Whee appopiate Ie

gie optios fo chagig some of the

desigs to see as aiatios o futhe

poj ects. Bu t this book is moe tha

just poects. The bed desigs coe a

wide age of woodwokig techiques

ad ca ead to the mastey of a

equaly wide age of woodwokig

skills. Tapeig log posts lamiatig

big cues cuttig ad smoothig

gaceful shapes ee ceatig age

oud postsall ae a pat of the sta

dad epetoie of the bed make ad

cabietmake.I the ist chapte I walk you

though the basics of buidig beds

What follows ae ie bed poje cts.

You ca p ick a poj ect based o good

desig fudametals that ca expad

you woodwokig capabilities O

you ca use these basic desigs as a

foudatio fom which to desig you

ow bed

3


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4

C

BDS CM N a shapes, szes, a

kis. Thee ae ozes o bascorms hres o ieet stles, a thosas o vaiatos Howeve the ol esseta part o a be is what we acta le owa seep o. This sall meas a mattess oe orm o aothe I act the wor be"was orgia se to escbe st the beig the wo bestea appe to the otheparts o what we ow thk o as a be. With

all o this variet t's sprisig how simarthe basc costcto o most bes is

BASIC BED

OMPONENTS

A

tpica be has a heaboa ootboar, seras, a some sot o mattess spport. Nota bes have all these partssome are ttlemoe tha the mattress while others a oa sorts o etras. B t whateve the be co sists o, th ere is oe almo st versal eatrekockow oier Ths is simpl a matte opractcalit A be is st too har to movearo as a igle it so each compoet s

iee a separate pat Well cosie each othe pats separatel beore we ook at how topt them togethe

The headboardThe heaboa is sall the vsa ocs othe be It estabishes the ook a the stea is geeall the most orate pat Its a

goo place to show o o skils as a woo

worke as og as the esig s wel itegratethoghot the rest o the be

a tpcal wooe be, the heaboacossts o the two legs or posts at the heao the be, the heaboar ra a some sorto a boar that etes p above the mattress.The term hadboard s sometmes se toescibe st ths boar at other times itescibes the complete heaboar assembl

icig the legs, ails a o corse thsheaboa plak. I wil se hadboard toescibe the assemb a hadboard plank toescibe the pak

Fctioall the heaboar keeps the pilows om slppig o the be a the waom gettig irt om cotact with heasa hai ols the othe ha the hea

boa oest awas e p agaist the wallSome people place the be i the mie othe oom. The eteeth-cetr writerMak Twa pace the ootboar o hisate talia be agast the wal. With pows agaist the ootboa he col look atthe beatill oate heaboar ow b hiseet whe i be Most people are ot qteths eccetic

Heaboa heghts ca va om st highe tha the plow to ma eet hgher thathe mattess his s most a matter o stlea esig althogh a ow heaboa makest eas to kock o hea o toss atr at ight I ecomme a mimm heghto 0 . to 2 . above the mattress.


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Parts of a Bed

Hadoad ank(o hadoad)

oooad g o pos)

adoad lg (o pos)

Mass so (h,a sad sppo)

Foooad ail

B D B L D N G B A S S 5


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Te footboardTe oooa s ote a scaleown vesio

o the eaoa elecg an compemet

ing e heaoas elemes. I can e ascompe as e heaoa o as smple as wolegs a a coectig a

e oooa ca e simpe ecase ioest have as mpotan a ncton as eeaoa gal t ma ave hepe tokeep e mattess in place. ow it's most aesig coventon tat as vsal alace tothe e

Some peope on like he coniemeto a ootoa. Some o't ke te ac at makes eang wth shees a lankets alitle moe icl. es n e vsalan psical cose at e ottom o thee comotig Coosng a ootoa esigneall comes ow o pesonal peeenceWhen o make a smila eaoa an

ootoa, oth at oce so a onee to se t p machnes an igs ol oceo wok o o

Te side railsThee sall s't a wole lo to he sieails eon olng evetig ogehe. nmost es the ae simp ectanga oase easo that e se as ot ge all tatmc attetio s ta te sheets ao akets wil oten cove tem. Howeve, tee aepet o was o ess tem p. specal on

es wth cves, te se as can echo acompleme te esgn.

Sctall te se ais conec teeaoa an e ootoa an sppo themattess Ths is accomplise mos oenw some sot o kockow awae so hee oes have to e move n oe pece.

M E T L R E S & WO O D E N H E D B O R D S

' aly coon to ee a bed wth a

woode headboard ataced to a etal

bed ae. Soe etal rae coe wh

a bracke or t p poe. Yo crew hebracke o he headboa d o bot nto a

headed net n the eg), te lde t

onto te pn on the ae.

Tee knd o bed a e c eae

to ake, bt te conecto betwee a

etal bed ae ad a woode headboard

a l ly q te wobby The etal ae

o degned we l o th prpoe, and

te conecton too low to o d he

headboard ecrely. tead, yo co d

try attach ng t e h eadboa d d rectly o

he wal l .

B E D B U L D N G B A S S

M E T A L B D FR A M E A T T A CH M N T

Wood

hdod

Bols dhrddiss o

scrs

l d m


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Box-Spring Supports

Box pg hae a gd fae ad o eed pport oly al og e edge.

A N G L E I R O N

K I N G S I Z E B E D

h

k-sz bd ds a s s h h il fh w- bx s h lsa f h sas

O O D E N C L E AT C H A N N E L I R O N OR A LU M I N U M A N G L E

Sws

S al

Hardwae designed

fo the center

support on a ing

size bed maes

setting up and

nocng down the

bed easy. Simple

ange bracets asofunction wel

B D B U L D G B A 7


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ATTRESS UPPORTS

Te las major comoe o a bed s some

hg o sor he maress his ca beeher a box sriga woode rame coaiig srigsor a laorm odaio

Box-spring supportsMa beds have a box srig as well as a maress Accordig o he eraioal Seerodcs Assocaio SA, a bo srg ssod alog wi abo 0 erce o e ma

resses i hs co r Box srigs aredesiged as a semirgid sor Te caabsorb some o e imac o a erso sig,lg or eve jmg o a bed, whc rologs e lie o e maress Ma eoeid he srg sor o a box srig morecomorabe a woode maress sors.

rom a bed blders vewoi i is easiero bd a woode rame bed or a box srigWile a sme maress eeds slas or a a orm o sor i, a box srg is soredarod he edges a b a kig-size bed, asime woode cea or eve a seres o maress hager iros screwed i lace arod esde o e bed ras is eogh a kgsize bed wic ses wo wsze boxsrgs side b sde as he odao o

eed a sor rig rom eadboard o

ooboard dow he midde o e bed ad a leg e midde o is sor

or ears, I js aaced is ceer s

or wh smal age brackes is coed we b ad o be screwed io lacewhe seg e bed Now here is a secic ece o kockdow ardware avaiabejs or hs rose Is a le harder osal e sho ha e agle brackes, bwe seig he bed o ca s droe sor o ace

Patform foundationsThe aeraive o e box srig is he laorm odaio, whch ca sor maresseswiho a box srig here are wo commoes o laorm sor slaed ad solidwhch is made wi lwood o r similar sheemaeral I roe, saed odaos,oe sig lamiaed sas isead o soldwood oes, are ver commo I is core erm platfom bd sa meas a lwood sor srace

mc reer sas or maress sorSas have some gve ad so ac ike woodesrigs w each sla movg ad exgideedel o he oers Ts makes orrmer sor a a box srig, b oe ais sll exible Aog idvdal sas ma

o look srog eog o sor eole

P L A T FO R M FO U N DA T IO N S

Wio a box srg , a maress ees o be so ed across is eie eg a d wi

SLAD

ooden cea

8 B D B U D G B A S S

SOD

Rail

Cla

Pywoodplaom


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withot breakig oce weght is dsibedacoss em te hod p ve well ad teirspport is te good. Slas aso allow he

matress to beathe" rogh e spaces owhatever as woh.

Sas are a bit more work to make tha asmple pwood plaorm. The also will movearod ove time leavig parts o te matess spported less o povide someom o algme or atacmet Slas arealso better a a dieret kid o movgaod: he are ve portable especia i

there ped togeter ad strapped io twobdles whc are mc easie to move taeiter a bo sprg or a see o plwood.

A plwood plaorm has is ow advatagesad disadvaages A plwood patorm s lesstrobe to make; bt withot sgicat spport deeath eve a /-i.- thck plwoodplaorm wil sag. Ulke the slas e etiepece o plwood eds to sag as a iSaggig plwood is dete o comortableto seep o becase o spie wil mach hesag However a recessed bo esig o heoo ca eas sppo a plaorm o a bedszes ecep the kig There o ca addadditioal sctre iside the bo Yo caalso se woode or meal strts dereat tospport a patorm wihot a bo.

A well-sppoed pwood plaorm is ieto sleep o althog stil rmer a a slatedplatom. Ulmate his added irmess cashorte the ie o a matress ess the maress is speccall desged or patom se.

A ver dere sppo problem s createdb waebed matresses. Tese shod aveplwood paorms b te ms be eioced wth a more eesive gid strctre

deeath to hep disribte e weght othe waer over a geate area o te loo.Amos a bed desg ca be ted ito awaterbed b addig a spport gid dereahe platorm. here ae commercial avaiablemeta ames that do te same tig.

IZING A BED

To te sleepe the mos importa part o thebed is the matress. I te bed ad plaormare strctrall sod te matess deer

mes the como o te bed To te wood worker however oe o ths s o mchierest. The mos mporta thg a woodworker eeds to kow abo a matress s issize ad is s a big deal ideed.

Matresses var i sze more ha eogho case bg pobems or e woodwoker.The sadad matess sizes I've ecoteredae isted i te cha o p. 0. I se hem as ale o tmb becase variatios i size ae

ie commo. ve come across matressesta were as mc as 1 i wider o arrowea stadad Te lesso here is that is verimportat a o measre te leg adhe wd o e matess ol be sig wihthe bed. Bt dot make a woode bed to it aslighl desized matess becase a bedshold otlast a paca mattess Itcold become diicl laer o o id aoher

dersized matress.Mattress hickesses var ar moe ta

hei widh ad egtp to 9 i . Mamattresses are sil made rogh 6 i. o 7 .thick. Bt he ed te idsr s to makethcker ad thicker mattresses. Some ca beaod 1 i. o 5 . tick. Ths ca eallcase problems o a bed desged o a 6-to 7ihick matress b coverg al or most

o a headboard ad ootboad. I o wa t ose a t hck matess ads t the popoios ote bed o accommodate he added blk

his grd nsde o

a box is one way

to distibute the

weght of a water

bed mattress ove

a ager aea. A

diagona grd s

also a possibity.

B D B L D N G B A S S 9


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Mattress Thickness and BedProportionsatesses ca ay by to 9 hckess. Desg eadboa ds

ad ooboads o accomodae e actal tickess of e matess

yo w l se

The mattess isay oerwhems this bed

The same mattress its this bed whch has a taer headboard and footboard

B D B L D N G B A S S

SNR E SIZES

Sandard Nam idh n nh n

wn 75

u r u 54 75

Qun 0

n 7

arna in 7 84

Determnng correctheadboard and footboardra engthsIts eas eogh to ow o wat the istace

betwee sie ais to be abot i. to i geater tha the mattress is wie Its aothermatter howeve to taslate that measremet to the eact legth o the heaboaa ootboa ails. his egth epes o acombiato o the space betwee the ailsthe with o the egs a the sie ral thicess A scale or l-size rawg wil o the

ob. Bt Ive evise two ormlas escribe iDetemiig Rai egths

BED HARDWARE

The eal tic to be big s pttig al othese pats together A o have to o it a wa th at s ve rgi a able whe the

be is together bt stil eas to tae apat ormovg o stoage here ae ma was toaress this pobem bt ew that real solveit we.

Bed boltshe best sotio that Ive o is stil acompromse be bots I re o these i oeorm o aother o amost al o m bes. o

other asteer has the same reliabit heoit is ve soi over log perios o timea ca be easil tightee ecessar Thee


19/196

are dawbacks however t's ot he easiestwa to assemble a bed Yo have o have theecessar wech i order to se p o disas

semble he bed ad o have to keep taco both the wech ad he bots whe hebed s moved o stoed Ad bed bolts sareire holes he otside aces o thelegssome people d he holes visaldistracg

Bed bots come seveal stes Yo casill b he taditoalsle io bed botsome orm o which has bee sed i beds or

ceties These bolts have a sae head

a wide lage to seat secel agaist thebotom o he hole ito which the'reecessed, ad a poed ed to help thead

easi ito the t tha s embedded i theral he also eire a specia bed botwech Ma woodwokig ad spealtperiod hadware catalogs car boh the boltsad the wreches

Yo ca aso se simple hexhead bolswih ts ad washers rom a hadwaresore These are coveet to b ad alite easie to se becase o do't have o

embed the s carel ito he ras

E T E R N N G I L E N G T S

hese wo fomas may ook a ie oth eds, we s se X stac

itimi dati g, hey'e acay ig (XY)/ wice s he same as s

qie simle oce yo kow what al tacg X). At ths o, yo hae

O a ed whee the egs o ais

may e diffee sies, yo'l eed

hs foma

the ees mea Oy simle math s the distace ewee teo shol

eqed des Add he two teo leghs

W X1 Y 1 - X2-Y2 T1 22 2

W (x y) (t x 2)

o aslae this ito Egsh, we

wa o fige o he legth of he

headoad o foooad a whchwe cal We kow the widh of themaess Addg i o i oha wdh ges s W, he distace

we wat etwee the sde as

Next we eed to kow the dis

ace ewee he sde als ad he

sid e face of he leg If the side ai

s ceteed he leg, the his ds

tace s eqal o the hickess of the

leg X ms the hickess of the a

Y dided y two As his mease

met eeds o e sacted fom

fo a oea ai egh

H E A D B O A R D A N D F O O T B O A R D R A I L A N D L E G S

Location of side a

Tenon

mattress width plus V to Y1

X

X

leg thicknessY

=

ail thickness

=

tenon length

Y2

2

B D B L D N G B A S S


20/196

Bed Bolt Joints

T R A DIT IO N A L B O L T J O IN T

Bed bots on s i de ai s to bed oss wthgeat steng

Embedded u

Bed aileg

Sub e ail

Shallw misei he leg

Cuebredhe f he headf he bl

H E - H E A D B O L T J O IN T

Ths woks as wel as tadoal bed bols headwae is commonly ava able

D-shaed ecess iside f ail

Bed ail

Nu

eg

2 B E D B D N G B A S S

dimeer dwe

Cuerbedhe f head

bl ad washe

Washe

06 hexheadbl

Bed bot oints need a way to pevent the parts rom twist

ing. A shalow motiseandtenon joint wos perfectly.

Dowes are an altern ative to the shalow mortise andten on and are shown hee with a hex-head bot oint.


21/196

B AR R E L N U T J O I N T

Barel s der ony n e shae of e ad the ecess They requi re cke ra l s a the oter

ypes o bed bos.

Fatbottomed

hoe on insideof rai

Bed rai

Barre nut

eg

H I D D E N B O LT J O I N T

Counterboredhoe for head ofbolt and washer

%" bot

Washer

I is ossibe o everse te orienato of bed botsand ot have a oe on e osde face of e leg

T-shaped recesson inside of rai

Bed rail

;," bot

Washer

Leg

.' dameterdowe

Tenon fromheadboard orfootboard rai

.' square nutembedded in

outer cheek ofhe tenon

Barrel nuts ae another variation on the bed bot.

Bed bolts can be hidden by revesing ther orientation so

that they screw in from the ail into the eg Ths requies

some ingenuity and a far bit moe wok

B E D - B UI LD I N G B A S I C S 1 3


22/196

he ae sghtl ae o wo w ngassembl, oweve, wh e loose washesa s.

To solve the pobem o sae stoage o theess commo assemb ool Ive aso sesoce-ea bols wch nee an Allewench to ghten Yo can easl mae aotch o e Ae wench o one o he seal cleats, so t's awas avalabe Howevelog soce ea bols ae ot eas o .

Usng bed bots

Whateve tpe o be bolt o se w notmae a compete jon b se It hos eal gt aganst e leg b oesn peventhe al om otatg o stg p ow ose o se Be bolts mst be se n con-

jcto w a locang ssem hat pevesths moton an eses pope agnmet.

atona bes a ve sho tenon o

the en o the al s te mos common solton. Ts teon plgs nto a shalow moseon te leg that sol be o abot / n o eep to avo weaeng the eg see etop awg o p. 12) e bol ns hoghthe me o te motseateno ot aseces .

An atenave s o se two /n.ameteowes oe o ete se o he bolt he

ae not ecessal as stong as a moseaeno jont bt hee st moe han songeog Don oge tat the bot a nthol the jon togete. he motse an eoo he owel s ot gle

H I D I N G T E E D O L T H O L E S

he easiest way to se a bed bol

leaes a hole o the otsde ace o a

eg Yo ca leae he hoes exosed

o coceal hem with decoaie

coes C ommecal mea coes

sa l y ot o the scew o whichhey hag some ae simle woode

mshoom lgs Thogh the wood

e lgs ook ie hey ted o al l

ot a d ge os oe ime Yo ca

also make csom woode coes i

ay sh ae o syle yo wat

Tth be told, do't md theholes ha mch ed o thk ohem he way thik o the scibed

layot l es a hadc doetai

jo They ae a s g o qal iy ad a

eectio o the way the ece s t

togethe Not eeyoe agees wth

me o this howee

4 B E D B U L D N G B A S S

op eft: Bed bolt covers swve on

a snge scew effectivey ding

te bed bot ole, but a lowng

easy access

op igt: Bed bot covers come in

a sur prsi ng ly wide vaiety of styles.

Some are made fom stamped

seet brass, but te ger quality

ones are cast brass

eft: e wooden musroom pug

s anote easy way to conceal a

bolt oe.


23/196

Barrl nutsA smple vaiaon o the bed bo and n u s

the bolt and bael nut The onl deence s

in the nu whch is a section o meal odwih a theaded hole unning hough i coss

wse Ths makes it a litle easie to insa the

nut: You ust dl a hole. Howeve his woks

bee in concept han in eali Bael nuts

impose limtations tha tpica bolts and nuts

don't. Fo example the on wok on ails

hat ae a least 156 n. thck. Plus hee is aneed o eithe consideabe accuac o a ai

amount o ussing to get he nuts to wokpopel.

S C R E I N G I N TO E N D G R A I N

Hiddn boltsThee ae was o use bed bots wihou leav

ing holes on he ouside o the leg You just

switch the oenaton o he bol and nut soha he nut is embedded n the leg and he

bot s inseted though a -shaped ecess on

the nsde ace o the side ail The wide pa

o he ecess allows ou o tighen he bolt

once i s ul in its ho le. You'l ind his vai

ation on the Casman-Stle Bed on p. 90

he Patom Bed on p. 130 and the Slegh

Bed on p. 144

Othr bd assmblyhardwarThee ae man othe tpes o commecial

mechancal asenes avalable o assemblng

For greater g i , i se owels i o a s ie ai so te

screws ca bte to og ga

Knockdownhadwae

Dowels give scewsbette gip

Hee ae a few

of the many bed

ra fasteners out

on the maret:

ho os, sldng

eys, cams, and

other nterocng

mechansms.

B D BU I L D I N G B A S I S 5


24/196

O O D E N K N O C K D O N J O I N T S

o joi he sde ra ls o he head board ad ootboard legsthere are seeral wood ots hat wi wok ee ae wo good

examles

TUSK TENON

Side ai

Tapered wedge

TAPERED SLID NG DOVETAIL

E D D N G A S S

beds icorporatig varios kids o hookswedges, cams ad screws. The atracio omos o hese is h a the are ivisibe rom

the oside o the bed. Most are qite coveie becase the dot reqire tools toassembe the bedo js sip oe par iothe other ad psh dow. ortael moso them ail to make a joit hat is either rigideogh or drable eogh over ime

There are a ew thigs o cosider whejdgig the potetia o a paricar aseer.Firs do o have to screw ito ed grai o

attach the asteer o the bed rai? his is apoeial serios problem sice screws wilevea pll ot o ed grai To help sovethis problem o ca drill hoes i the raiad iser dowels perpediclar to he screwhole. This wa the screws wil pass hroghthe og grai o he dowes

ex is he hardware ise wel made?Look or the srdies hardware o ca d.

Does i t icorporate some orm o a wedge otighe the joit ll? The wedgig aciothat comes rom a apered prog or hookaows o to tighe he joi simp b tappig dow o the rail i it ooses over time.

I he hardware passes hese tests I ikeo tr ot the asteer i a mockp joi t osee i it's eas to isall ad se i there area sa dimesioal reqiremets, adi it makes a rigid eogh co ecio.ortael I have od a perectsoltiosat leas o et.

OODEN KNOCDOWN

JONTS

here are was o make a bed sig woode

kockdow joits, too. These are ot vercommo bt he ca make soid coectios ad ierestig additios o bed desigs.There is a commo problem wih hese joisoe par either the side rail or the headboardor ootboard rail eeds to protrde o romthe bed edge so ha there is eogh wood ora solid joi t. his ca be brta o shis. Yoca trai orsel o walk arod, bt sill

have scars rom m raiig period I do'tse hese joits a more.


25/196

An Under-Bed Storage Box on Wheels

To use good sorage space uder he bed,buid boxes o fxed casters. They roll in andout from nder te bed ike drawers.

Fxed castes ensue

that the stoage box

tacs eativey

staght as t sides

out and bac unde

the bed amost as if

it was on dawesl ides.

STORAGE UNDER

THE BED

Undethe-ed stoage s a geat ay to se a

age and otese ased space Afte expe

entng th al knds of eods fo ang

ng daes o the ed ae Ive decded

tha havng a dae ox ol on the gond

oks est My desgn s vey stagfoad

t's js a ox castes set nto he ot o

I se e-hee casteste xed knd

no the sveng onesand the ox pls o

8

1 above foor

C R O S S S E C T I O N

O F M O U N T I N G C AS T ER

Plywood bottomof box

Bock for

aost stagt as f as on dae sdes

Yo can pl te ox o oxes) all he ay

ot fo nde te ed hch s a g advanage ove daes onted to te fae

hee ae o the ess copcaed ays o

ake e stoage ox oll Yo can get vey

lo poe cases and also specal ed ox

heels a sce o the o tsde o the ox

B I lke e eel o te 2-n e-ee

castes and ey oll el on os sfaces

thogh oldn' go so a as to ncde

sag capeng

Side ofstorage

box

1

B - B U L N G B A S 1 7


26/196


27/196

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------

T

his bed is basic unadorned

and simple It's an ideal first

bed project because its very simplicity

also makes it perfect as an introduction

to making any other bed. We examine

all of the basic elements of making a

typical wooden bed in this chapter We

use some variation of these methods on

all of the beds in this bookexcept for

the Platform Bed which has a diferent

structure entirelyso this project also

functions as an overall reference

This "first bed has a simple head

board but no real footboardjust legs

and a footboard rail The bed sets up

and disassembles easily using bolts

with washers and nuts. The side rails

support a series of wooden slats which

create the platform to hold the mat-

tress The whole thing is easy to store

or move around since the parts are

reasonably small and relatively light

This bed is also a first bed in another

wayit's a good first bed for a child

because it's a little lower than usual

But it certainly doesnt have to be this

wa You could add 2 in to the legs to

bring the rails up to 10 in. of the foor

making it a more typical adult bed.

give the basic dimensions for the other

standard sizes as well, since all o f the

techniques and approaches described

here apply to any sie bed; just the

dimensions need to be recalculated


28/196


29/196

18'4

5"

8

8'

1

" hoe

386 (ee he dea on 1)41/6

V I E W FR O M I N S I D E O F B E D

35

I you chooe o ay ou he headoard a a ell e, i ha a majordiamee o 41 ad a mior dia meer of 23

1

Teo doed lie)

" hole wih %"counerore

5"

8

V I E W F R O M O U TS I D E O F B E D

+-75

&

Clea ide rai

S I D E RA I L J O I N E RY

Bol hole

S I D E R AI L

C U T L I S F O R F I R S T BED

H e a d b o a d a n d F o o t b o a r d

ea doa d o i. x . x 8 i .

Foooard o i. x . x 1 30 .

Headoad ad foooad rail H i. x 5 . x 41 % .

Headoard lak Y i. x 8 i. x 39) i.

S i d e R a i l s

Sde ai 1 Y . x 5 i x 75 i

lea 1 . x 1 i. x 75 .

15 Sa % i. x 4 i. x 39 i .

H a d w a e

4 Hex-head ol wh & waher 06 . x 5 i

8 Dowel (for alime )

30 Dowel (fo la i)

#6 x i cew

#6 x 1 X-. dywal crew, a eeded

06 i x i.

i . x .

Note: These dimensons ae fo a twn-size bed Yo may ave to adjst yo dimensons to suit the bed sze, te mattess sze or any deences n wood dmensons.

F I R S B D 2 1


30/196

UG --TE

Tip f you cut a

tenon too loose you

can glue a thn

atch of wood onto

the chee hen

eft the tenon

erl

TH FRST BD eaks dow to foasc cooes: e headoad te

ootoard he sde ras ad he atress so It's est o work o he headoard adootoard at te sae te sce te work sso slar ad yo wll save set te oeach of the ecessary stes he sde rals

coe ext sce tey colee the ed fraeally work o th e slas

HEADOARD AND

FOOTOARD

Making and mrtisingte psts

1 Ml te sock fo the or osts to 1% sqae the ct te to the egts dcaed he dawgs2 Lay ot ad ct he headoard ad foooard ral orses o te er faces of theosts A 3og wde ad V-dee orse ceteed o te wdth o theos works wel or all ed szes O a chldsed locae e ottos o te ortses 9

ENSIONS FOR OHER SIZE ESo u qu or ay o , mpy u m

o po ow

Note: Remember to adjust you Cut List accordingy.

Legth betweeeadboadteos & foot-boad ais (A

Fu 5

Qu

aifria i

2 2 R T B E

Widt of Ovealeadboard headboadpank height

38

39'"

1

Side ralegth

5X

8X

8X

8X

ro he ottos of e osts O aadl-sze ed the otses sod sart 1 1 fro he os ottos I se a rote ad aotsg jg o do ts wok (see Mortsgg for Rotg T Workeces")

3. Mak o ad c t a addtoal otse o each o the eadoad osts or e headoard

sel Ts s a log sallow ortse9 log wde ad dee

Milling te rais1 . M the eadoad ad ootoad ras tose t o to legth o shold also the sde als ow sce they ae the saethckess ad wdt (t he s et te asdet yo'e doe wth the headoad ad

foooard) 2 erfy tat he hckess of the oss sactally % ad ta the thckess o thesde als s actaly efoe ctg herals to the dcated egth I yove gotars ta are dffee eher y desg oy aestace yo eed o calclate hecorec al legths (see Deeg RalLegts" o 1 1) .

Tenning te rails1 Mark ot he locato o te teo so thats ceteed o he ral fro sde to sde ado o to otto Mark the egt o teteo as wel o oth o these asks refe

0

C

+-A


31/196

Mortising Jig for Routing Thin Workpieces

Optional stop to register

bottom o workpiece

Workpece clamp lushwith top o ence)

These acesmust bepependcular.

Bench hold-down clampattached to mortsing

block clamps can be usedinstead o hold downs on

ager pieces)

S I D E V I EW

Router ence

Workpiece

Bench holddown clamp

Auxliaryence

Guide stp

Mortisng pacer blockblock

Tis mort s ing j ig o lds n workpieces, suc as bed

posts, a would otewise be diicul to moise

wth a route Te bock is essenia l y a arge piece owood mi l ed a and sq are at supports e route

base dur ing e ct. A gui de srp keeps e route

fence gt o e bock dur ing e ct

With the post

clamped to the mor-

tising block, the

router s steady and

easy to hadle .

F R T B E 2 3


32/196

A Tenoning Jighs g he ps yo t a rage o teos au

atey. ts wo as ompoes ae a workpiee spport whih atahes o the part to

e teoed ad a epae whih guides

the ts.

Brace

ece

22"pacer bloc

B O TT O M V I E O F J I G

9"

2 4 R S B

ece

pacer bock

F R O N T V I E O F O R K P I E C E S U P P O RT

-"

Ruer

B O T T O M V E O F T E N O N I N G T E M P LAT E

maple trip

Ruer

6

B U I L D I N G T H E J I G

t2W'

1 Aemble all the part o the ma i body o theig (horizota platorm, orkpiece upport,pacer block, ece, ad brace).2. To aig the teoig template o the horizotapatorm o that the guide trip o the tempateill cut teo paralel to the edge o the orkpiece upport, clamp a thick by ide reerece board to the orkpiece upport o that itexted through the opeig i the horizotalplatorm

3. Place the teoig template o the guide tripi lied up exactly ith the reerece board adclamp the template to the horizotal platorm

. cre the to ru er to the bottom o thetemplate o they it tightly agait the horizotaplatorm


33/196

o se a arkg gage, yo ca aso easre a ark eer a pecl or a kfe2 Ct aay te aste Te tool se osofte to o ts jo s y pge roer a aspecal eog g see A Teog Jg) Te g orks t a pge roer a gesg tat folos a ge srp to ct teeo Te locao of te teo ca e corole y ere yo posto e eogepae o top of e orzotal pator ofe orkpece spport3. Cap te okpece to e orkpece

sppor a ege agas te ece ae op fs t te otto of e teogepate ocate te epate aove e orkpeceere yo a to c te teo a clapor scre pace5. Pt e oter o e g a set eplge ecas o te rgt ept Tr ote roer a pge to te f ep of ct

see Cr oss Secto o Teog g Usea p Ct te teo ase ay gpasses To ct e oer ace of e teoove over to e opeg o te ote seo e ge strp Cse o ct e ase fro te ses ofe eos a ro e over t a raspto atc te roe es o te ortse (see

o p 26)

ip When ung he enonssa wh a ve shaow cmb

cu hen wase away he es ojhe wood.

C R O SS S E C I O N O F T E N ON I N G J I G I N U S E

Route

route bt

ude tp

orkpece

pacer block

Bench ve

eong template

n gude buhng

Horzontal platorm

Bace

okpece upport

hoto A Th tnon

ing ig postons th

wokpic pight

and suppots thot on th nd of

th a.

R B 2


34/196

hoto B Rasping thdgs of a tnon is

quick and asy. ts a

ot asi to mak

th tnon fit a out

d motis than to

squa up th nds

of th motis

2 R T B

After yo ct te teos ceck te it oeac ivaly I se a specia aet plaeto fit te ceeks t a rasp or sapaper o aock orks also Be carel ot to o overo tape te ceeks o sol ave a sgfit tat yo ca pt togete y a

9 Mak te teo a te corespoigortise it te sae lette o er as

soo as yo'e oe fttg te s il otoly ei yo ere te joit goes t italso serves as a reier tat yo avealreay t te joit

Makng te eadboardf yo ca f a sigle --ie plakfor te eaoa se t O a tale tisol oraly lea to arpg t ere telog otises i te posts keep te plakstaigt I yo o ave to gle p te eaoa coose yor oo caefly or a gooatc Reee te eaoar s sayte vsal focs of te e

1 . Ge p te pak fo te eaoa ifecessary) l et t y t e ake it lat a

soot Make se te otto ege sstraigt

2 ge te egt y caely easrigte sole-tosole egt o f te eaoar ra a a i for te to -teos se te rai tself as te rer to arko te egt3. Cossct te oa to legt reerecigot cts o te sae ege o ay at toseak p o te proper egt fst cttiga lttle log te takig a lttle it off at atie tl te eaoa is pecisely te igtlegt a exacty sare Te eaoa sol ave a ce gete

cve alog te top ege Mak it y sprigiga ti pece of oo to a cve sig aclap ti yo ae satisie t te sapea trace te lie it a pecil Dot ct tote lie jst yet see pt C)5. eo te es of te eaoar Tis sot a oral teoits very e a veysot e sipest ay to o t is to rotot sies of eac e it a V- raetig

it Set te ept of ct o te roter so yollleave jst over ts so ea cttg jst er i eep o ot sies ofte / i tick eaoa Back p teeaoar ere te roter exts te ct Ct te cve o top o te eaoa oca se a asa or a jigsa te plae orsa soot7 Mark te eaoa teos 1 fo

ot te oo a top eges a ct aayte aste Tis sol leave a teo tat isaot i sorte ta te ortse leavigroo o expasio o ot ee to roove te es of te teos or sare p tees of te otises see t o p 29). it te teos to te ortises a akot alves o te joi t so yol ko atgoes ere later

Dring oes n te postsfor te bed botsTe kocko joits fo te sie ails are asiple verso of taitioal e olts eeae tree oes to ril te eaoa aootoa posts o eac jota ceta oltole a to o les o aliget ps ae

o oels Te pis alig te ra properya keep t o tistig or siftig


35/196

1 . ay ot e oatos fo te bol ole ea pos. Tey sould be exay eteed ote post ad h n. p om te botom fo ads bed o

hn. up fom te botom fo

a standad wn bed.2. Lay ot te oes o te algnmetps . above and n. beow te botoles as meased on etes3. To dl te ee oles te posts I makead use a spea jg (see A Bot Ho e DllngGde" o p e ee oes ave toalg exatly on bo te poss ad te als

so osstey s esseta One youve dledte bol ole a post (ete on tedll pess o wt doweng jg) yo anse s jg to agn te -n. oles above adbelo. Te as ole to d s e onteboed/-.damee ole o e ousde o tepos I yo dot ave a -. ou ebongbt wt a plot you sould t s ole

befoe e ee o te oe sde. Mak anddll e /-n. ole abot n. deep fom teousde Te dll og e ente of eoe w a . b en make and use tedlng gude to dll e / oles fomte sde as desbed above

Assembling the hadboadand footboad

1 . eoe assemby aefly pane sapeand sand (n wateve ombao you pee) all pas smoo. You mg aso wat oadd a small ame o a o te edgesabou . seems abou gt. pu a bggeamfe on te tops of e possmoe ke .beause I k t looks bete On tepos bottoms te ame elps keep woodfom spltg o ppng o ff wen t e bed smoved aoud2. Gle up te eadboad fs pead gue one of te al motses ad ten vey lgtlyo te oespodng a teon. oo mgle on te teon wll lead to squeezeotnse te a teon as fa as you a byad e set e eadboad eon ote log mose n te pos oweve don't

apply ay gle o te eadboadpost ont.Appy gle to t e al motse ad teno onte oe sde.

hoto C Spinging an vny thin pc of wood into a gnt cuv s

an asy way to ay out th top of th had boad. You can oosn o r

tightn th camp to fin-tun th shap.

R T B E 2 7


36/196

A Bolt Hole Drilling GudeT i s s i p le dr i i ide esures os i se

paeet o te eta l ol oe ad a ie dowel oles Use a dr i l pess o ake

sure e oes ae stra Ts j i a e

used o dr i l e oes i ot te poss ad e eds o e s de ra i l s .1

Hard ma ple with grain running lengthwise

%"

II

3/8" diamete dowel

r - _I l " i

/"

I TH G U I D E B U S H I N G S

Drill ushng

or a moe durae jig ,inset hadened drillushi ngs or a -indrl l . ude should e aittle thicker than theushings are long.

2 8 l R T B E D

ude strip alignsthe jg when used

to dril the holeson the rail ends

2V

%,'

I

_ " i - /

2% "

I T H G U I D E S TR I P

Hoes arecenteredon lock.

5/6"

1%,

Clamp

Rail


37/196

3. Camp te assemy togeter sowly witone amp on te front of te assemly andone on te ak to equaize te lampingpressure (see pt on p 30). You mayave to a djust te position o f te eadoardso ts parallel to te ra n order to amp tup tgt

. Wen te eadoard is assemed pin teenter n plae wt a #6 y 2 in srew.is also eps keep te souder of te ead

oard tigt against te post. Drl te piotoles so tey ome troug te legs enteredon te ends o f te eadoard. Countersink

Tip: Yel low glue sets qu c ly soyou have to move fast o hel

wth lage ects get eve

thng eady befoe statngChec that you have enough

clams and enough om to

wo lay evethng out n away that hels me emembe how

t all goes togethe

Photo Chiel away

the thin wate et

ate bandawng

the tenon end t'

eay to get a precieuace by hand

becaue the chiel i

guded by the tenon

houder.

te oles aout / in deep so you an pugtem after asseml

IDE AILS

Miing and cutting te aisto lengtMi te side rails now if you avent areadand ut tem to engt. Wt a ed made

speially for a ld its est to eave verylitte room around te mattress anoroxspring so te ild ant slide down into a

R S B E D 2 9


38/196

Photo E: When clamping up the headboard assembly, use two clamps on the rail-one in front o the headboard and one

behind-and ofset them slightly.

3 0 F I R S T B E

gap or shift things arond when sing the bed

as a trampoine75/ in long is fine on this

bed. But or an adult bed with just the mat

tress on a platform o sats, its better to make

the rail between Ih in. and 1 in onger than

the mattress This leaves room or tucking in

the bedding and or taler peope to hang their

toes of the end

Drillng holesfor the bed bolts1 . Drill the bolt hoes for the railtopost

joi nts. Beca se its not easy to dri perfectly

straight holes into the end o a 75-inong

board sggest using a se-centering doweling jig (see pht F . Dri as deeply as possi-

be with the jig, then deepen the hoe giding

the dril by hand.

2 Dril the dowe pin ocating hoes in

deep, using the same jig you made to drill the

hoes in the posts (see pt G ) I f you didn't

make that jig, the secentering doweling jig

wi also work.

3. Gue the 6-in by 1 /4in. dowels in the pin

hoes in the ends o rais

Routing the nut ecesses1 . To ct the recesses for the bed bolt nut on

the inside face o each rai, make p a tem

pate that wil both ocate the recess on the

rail and create the D shape (see A empatefor Roting Nut Recesses" on p ), and

clamp it to the inside ace.

2 h h b d % d


39/196

2 Wh a -n sraigh b and a %n gude

bushing n a punge oue, plungecu o a

deph no cose han lis n fom he oppose

sde of he ai, akng vey shallow passes.

Sop and bow ou he sawdus as ofen asnecessay o preven sawdus fom buding

up in he recess

3. Chamfer or ease he edges of he recess

Making and instalingthe ceats1 . Mi up sock fo he wo ceas (use scap

fom making he side als f you have )2 n one of he -nwde sdes of each cea,

lay ou he locaions fo /n dowel pns

Space hem every 5 n , saring 29/ n from

each end (or faher f he ceas are longer).

3. Dll he n-damee hoes ceneed on

he hckness of he cea, and make hem

abou n deep

4. Dill a seies of counesunk plo holes for

screws n each clea, evey 6 in or so and n azgzag paern abou / in. from each edge

he cleas wl be more secure hs wa Spread

a ile glue ino each of he dowel hoes, andpound n n by /4-nong dowels5 Wai unl afte you apply a fnsh o he

sde als before aachng he ceas This

makes he fnishng much easer

FINAL SSEMBLY

Making the sats1 . Mill enough wood for 1 5 sas ha are

n hck, and rip o n wide

2 ase all four edges of each sla by roung

wh a V4-in. roundove bi (ahough anyhng

ha breas he sharp edges s fne).

3 Cu he sas a ll e b over nshed lengh

for now. To ge he exac engh, you have o

acually se up he bed.

4. Once you've cu each of he slas o lengh

you can cu he dowel noches n he ends

do hs wh a jg (see "A Jig fo Nochng Bed

Sas on p 3) Howeve, hs jg only works

f youe makng a small bed o have a failyhgh ceing If you don', here s no reason

Photo F: Dri the -in. bot hoe in the side rai with a sef-centeing

doweing jig. It centers the hoe wel and is simpe to use

PhotoG:

To cut the 5/16-in.-dowe aignment hoes in the side ais, use

the same dil ing guide you used fo the posts

F I R S T B E

A T l t f R ti N t R


40/196

A Template for Routing Nut RecessesThs s mp e tepae akes a qu ick ob o

cttg e t recesses o he s ide faces

of the sde a ls .

Plunge oute

%" gude bushng

:a"o V oute bit

Bolt hoe

okbech

3 2 FI R S T B E D

Ra i l

1 hoe

TOP VIEW OF TE MP LATE

emplate

3%"

W' to%"

thck

+-

5

14

Camp

Chise or fie awayto leave enda

you can't cut the notches on the bandsaw and Ti H d l th b t d f th


41/196

you can t cut the notches on the bandsaw and

clean them up wih a chsel. To check the

o the slats, you'll have to assembe the bed

Atach the c eats once youve fnished and

waxed the bed (see the Appendix on p.

or nishing suggestons) Line hem up ush

wth the botom of the sde rais, and screw

n pace.

To attach he sde rails to the headboard

and fooboard ean he headboard uprght

aganst a wa or somehing secure, and pace

the side rals roughy in positon. Place a

16-in. by 52-in hex-head bolt wth a washer

and a second washer and nut a each corner

Inser the dowels on one end of a sde ra

into he correspondng hoes in he headboard

post. nsert the bot and washer rom he out

side o the headboard, until he end of he

bol s jus coming nto the nut recess. No w

place he other washer on the end of he boltand thread on the nut t helps to rotate the

bol from the outside of he bed when youre

doing this (see ph H).

Tip: Hard male s the best wood for the

slats-t has good stffness and s trength. Ths

s less of a factor wth a narwer bed Any

tye of wood you can get nexensvely s fnefor a twn.

F I R S T B E D 3 3


42/196

A J I G F O R O T C H I N G B E D L T S

This j ig lds he slas vetical y s ha perectly squa re nces ca b e ct n te table saw wih a dad blad e Theig bdy s cmpsed tw ba ds jned at right a ges. A ece hat sraddle s te tabe saw's rip ece gu des

he ig tugh te ct

TABLE-SAW

N O CH I N G J I G

3 4 FI R S T B E D

F R O N V I E W

I4 -

Bed sat

Notching jig

Ths spacer bloc

is the same widthas the rip fenceand ides o topof i.

Rip fece

Cuttng the slat's dowe

notches on the tabe saw s

efficent and easy, but only if

you have enough room above

you tabe saw. The notching

jig hods the sats upright.


43/196

Photo J Dop the sats into pace with the notches aound the ocating pins in the ceats to

compete the bed

4. Use a -. ut dve to tghte up thebolt ad a -. ope-ed weh to keep the

ut om tug Tghte seuely but dot

tghte so had that youe ushg the wood.5. Attah the footboad to the othe edo the a the same way you attahed the

headboad. (Dot ty to put the bed togethe

by attahg the seod al beoe you attah

the ootboad uless you have he lp.)

Attah the ot he sde al to the headboadad footboad (see pt I o p. 33) Put

both of the bolt s (wth the washes) to the

bolt holes the posts beoe you pk up the

a Pushg both bots to the al w gua

atee that the loatg dowes wot adetaly pop out whe you wok o gettg the

washes ad uts o. Chek to see that al o

the bots ae tght.7. Dop the slats ove the dowel ps o the

leats hopg they t ad adustg them f

they dot The dop the mattess to plae

(see pt J) . Vo A bed.

I R T B E 3 5


44/196


45/196

.. -------_...... ----------_.. ----------_..------------_..--------_._...------_._..---------_._ .. .. .._----....------_._ ..---------

SHAKER-STYLE BED

T

he Shakers lived their lives

apart from the "world, what

they called life outside their religious

communities. They did a lot of things

differently from the "world, including

sleep Because the Shakers were celi

bate, they had little need for double

beds and used them only to save

space. Two en, women, or children

would sleep together in these.

Many Shaker-designed single beds

did not break down The side rails

were tenoned into the legs just like

the headboards and footboards

Almost all of the beds had casters on

the legs This made it easy o move

the bed o ut o f the way when sweeping

the foors The beds were also relative-

ly high of the ground to keep out of

the cold drafs near the foor.

This bed is not a copy of a particular

Shaker bed Instead I have borrowed

elements from a number of Shaker beds

I have seen. Some of my construction

details remain faithful to traditional

Shaker construction But have made

concessions to odern living and to

contemporary woodworking techniques

chose to make this a full-size bed,

which is more useful than the 28-in .-

to 34-in-wide and 70-in.- to 72-in

long originals. also omitted the

casters I hesitate to say that these

changes make the bed better but they

certainly make it more familiar and

comfortable for us toda

3 7

Shaker-Style Bed


46/196

Shaker Style BedT AS STRUTUR of he Sha kerStyle ed

s s i mi l ar to the i s ed. owever the es a reured the headoard ad footoard aks do

doue dy as sttua rai ls ad the eas are

iea w ih the s de a l des

Sqresetio

OHER E SIZES

Ril

Hedbordheght n cene

Foobordhegh ceter

Tw* "Quee

Fo tw ed shote the hedbod squresetio o 4 d me he heght o hehedord where it mees he eg.oe A kng-ze SherSye Bed s no ecommeded

3 8 H K E R T Y L B E

er

et

Ss

ot holeove

H E A DB O A R D D E TA IL S


47/196

H E A D BO A RD E N D O F S I D E R A I L

1 X"

"

1 "

oood

Rails are1 thick

5"

F O O T B O A R D E N D O F S I D E R A I L

0"3" + ,- 4"

;==

1 "

Ct

H E A DB O A R D D E TA IL S

eadboad le

3"

Shallowmortise

bolthole

1 X

Hadboard 1 thick)

14

3 to opposite e

1"

1 "

13"

The overall leth o the headboard ad

ootboard p aks (i cludi teos) is "

FOOTBOARD DETAILS

This curve is a sectio o aell ipse with a mior diameter o1 " ad a major diameter o ".

Footboard (1 thick)

3 to opposite le

2

2

O O DE N B O L T H O L E CO V E R

er

2

W

\ootbod g

H K R - T Y L B 3 9

UG T TT


48/196

C U T L I S T F O R S H A K E R B E D

H e a d b o a r d a n d F o o t b o a r d

eaoar pak

ootoa pak

2 eaoar poss

2 Foooar posts

S i d e R a i l s

2 Se as

2 ees or eaoar es

2 ees fo ootoa es

2 eas

5 Slas

H a r d w a r e

3 owels (or sla ps

1 x 2% . x 56 .

1 . x 1 3 . x 56 .

2 . x 2 . x 32

2 . x 2 . 26 .

1 . x x 76

1 x 5 x 12

1 x 3 x 1

1 . x 2 . x 76

% . x 4 . x 54 .

x 1 ;

4 exea ols w s a wases . x 5;.

ol ole oes . x 1 % x . k

# x sews as eee

# x % rouea rass srews as eeeThese di mesons are for a full-size bed wt a mattress up to i tick Youmay have to adjust you dmensos to sit the ed size, te mattess size oay deees wood dimesios.

Tip: he osu re n yell o glue

sells ood slg hly long on edgesW 24 hou rs before soo h ng h e

su ces o gve he o su re chnce

o evore nd he ood o sele

bc don

4 0 H K R - T Y E B E

ALTHOUGH THI BD ooks vey dfeent fom te Fs Bed on pp 18-35 e ovea appoa o budng s esame. To stat you wok on e eadboadand fooboad togee. en move on o tesde as and fnay te matess suppot. etuned egs ae not essena o te onstuton bu tey ae o te desgn. You an makete bed w stagt o apeed egs but wont ook as ne.

AING TE

HEADOARD AND

FOOTOARD

Miling the headboard andfootboard panks1 . M up e pees o te eadboad andfootboad panks.2. f youe not wokng w a snge boadpank gue e pees nto sgty oveszepanks.3. Cut e panks to sze makng sue eedges ae paae and te ends squae.

Cuttng the tenonss bed doesn ave a sepaae eadboadand ootboad a to povde stuuastengt so te panks temseves need stutua tenons. Howeve 8-n.- o 4-n.-wdemotseandenon jons woud beak apatdue o seasona wood movement. e ad

tona souton s to make a dvded enon (seeHeadboad and Footboad oney" on p. 2).

1 . Cu te eadboad and ootboad pankenon soudes wt te tenonng gdesbed n A Tenonng Jg" on p. 24 and a4-n.-ong stag bt o use te g w ewde eadboad emove e vea eneom e wokpee suppo. You ave o ute tenons a poon a a tme (see poo


49/196

2 ay ot te setons o tenon tat wll stayfl lengt an te sort /n. anes3. Ct away e waste on e bansaw anen pare away all of te an enon on tevery top an botom to leave solers

Layng out and cuttng t

curv on top of t planksTe eaboar an ootboar on s beave epal rves I yo're nfamlarwt elpse ayo see An llpse Layot gon p 7 Yo an aso se a smple rve asfor te Frst Be.

1 . Lay ot eer a smple rve or an elpsealong te op ege of te boar

2 Ct te rve o on te bansaw keepngto te otse o te lne

3. Clean p te sawn ege wt a pane orsanpaper.

Cuttng t lg jonry1 . Ml p te leg banks. Te t lst mensons are / n. longer tan nse. e exra/ n on te top o te egs s or te trnng

enters on e laeyol o ansmoot t to sape ater2 ay ot te morses for te eaboarfootboar an se rals as sown nHeaboar an Footboar onery on p. Remember tat t e let an rgt egs are no enal og ey are symmetral.3. Mar nes tat nae te en of te seons tat reman sqare all e way aross e

Photo A: One goodway to cut the u

width tenon on t he

headboard and oot

board i with the

tenoning ig on

p. 24 and a 4-in.

ong router bit.

H K E R T Y L E B E 4

Headboard and Footboard Joinery


50/196

ou e teo s ae he rado al way o o a wde heado ad to les. Wood oee a y

st c ause crack ecause te oera l oeet o te pa k s st l costaed. u thejos sould rea srucural ly soud. To e cack ake sue he wood s ey dy.

e hauches ae o ued ad ep keep te eadoad ro warp.

H E A D B O A R D L E G B L A N K A N D T E N O N F O O TB O AR D L E G B L A N K A N D T E N O N

"

/"

f3" 3"3"

+

3"

3" " t

13W13

4 2 H K E R - T Y L E B E

eadboard

14"

13W

"

" deepmortise

1'13"

ootboard

8"

X"

A L T E R N T I V E J O I N E R YF H E A F T


51/196

F O R H E D B O R D A N D F O O T B O R D

he head boad ad footboad a ks ae sucual o he di sadaae o ths echiqu e is tha te jo

ts bed. Whil e te adioa costuctio mehod s a may o kee te eadboa d a k as ht aa is te

diided eo wood moeme may cause cacki les. t also oes ess lue suface (ad stet ha

because he oea l moemet o he la k is sti co he diided eos. Us at hauches (shal ow teos,

stai ed. A a teatie mehod is o use a s e teo ea y) witout lue to ete sde o te teo hels kee

he cee. Ts des a lows o ucosa ed moe- he headboa d fom wai .

met a d tt e cha ce of cack

H E A D B O A R D FOOTBOARD

5"

4" 4 "+ eadboard5"4" 14"

t4"

blak at te top a botom. Yo ee thesemarks whe trg.. Ct the se ral mortses eep steep eogh to keep he ra rom wstgor movg ow he best tools for the jobare a pge roter a the mortsg blokesrbe Morsg g or Rotg maWorkpees o p

2" 3

1 " i

5 Also t he heaboar a ootboar mortses . eep over ther fll leg. hego bak a t e wo flep mortses . eep. Drll e /--ameer eep oerbore for the be bots o the otse ofea leg

ootboard

8"

H K R - T Y L E B E 4 3

Tp Use wood w th

straght, even gran

7 Drll e oles for e - exead bed bolts troug te legs entered n b T b l l

. Roug out te to and bottom o f teblan o ylnders w a rougng gouge

b d f


52/196

g g

for the legs. You

don't want much

gran runout on the

relatvely long and

thn legs because t

wll weaken them

consderabl

e ounterbore To ensure tat te bolt oles srag drll rom bot sdes and meet

te mddle ts te long way around o do but t esures a good resut

Turnng the egs1 . Mae u fullsale atterns of te uerand lower arts of te turngs o ees o. lywood 2 w de ad as lon g as teseo volved (see Mang te urnngPatern)

2 et u e bla n e lae.3. et te tool rest n osto or rouggout te yldral lower leg Rotae te legbla by and o e a te tool restwo't terfere wt te blan wen ssng.

Making the Turning PatternPywoo paes wt oes to o te p o a pe l e p yoa te tu i la aae y w e t s spi i te late .

stayg abou a way rom te edges ofe square seton

5 lean u e transon betwee ylnderand square seon usng a gouge worgslowly to te le. art e ut wt te toolu on edge e roll te gouge later towarde bottom of te ut eeg te bevel rubbg agast e sng leg (see o. ) If you just reset te ool flat (le asrag ool) youre lely to ear a uoff e edges o te square seton.

Usg a el transer te not loaosrom te attern to te snnng bla (see o ) 7 Usg a artng ool tur notes eblan were you ave mared to te varous dameters (see Leg urg trategy)ote tat you dont do s on every lne you

Brad to resteottom of turn n

\lan

F O R B E L O T H E S Q U A R E S E C T I O NM A K I N G T H EPATTERN

. Da the profiles ofthe tunin on thepyood. Ethersetch it out y h ando trace an enlaedphotocopy.

2. Dra perpendiculalines out to oneede of the patternThese ill late seveas depth-of-cut and

turnin-detai udes

Notches fo point

I of pencl

" " "

" plyood

%"

3 At each of theselines cut a shallonotch ith a nife ora sa just ienouh to hold apencil point

F O R A B OV E T H E S Q U A R E S E C T I O N

4 Ma the dameterof the le at each ofthe indicated pointson the patten

4 4 H K E R T Y L E B E

Cut aay the corneto prevent teaout onthe suare section

hen the patten is inuse

Brad to estefom the top ofthe turnn lan


53/196

Photo B: Ate

roughng out the

cyinder beow the


54/196

y

joinery bock you

have to cut the tantion rom quae

to round careuly.

he gouge hould

be up on edge a

you tat the cut at

the ne

Photo C: ouchng a penc poin t ightly in each o

the notche on the turning pattern eave an eay

viibe mark on the round leg bank hee mark w

guide your cut.

4 H K R T Y L E B E

Photo : Hod the ca per wth one han d and the parting

too with the other hand. he caipe wil drop over the

zed notch when you turn to the corect diameter.

Photo E Ater

roughing out the

hape o thi part


55/196

teo shoues. Check that the teos

ae ot too og o the mortises. hey

shou be about i. short. Otherwise

whe you gue up the joit may ot come

y togethe.

AKNG THE DE

ALS AND LATS

1 M up the .wie ais gettig a at

a smooth sace o both eges becauseyou have gue jots o both.

2. Crosscut to 1/ . og which eaves . o etra egth

3 Smooth the top ege o the ai wth ahapae ow so you wo't have to o this

with the bocks attache You ca o this ate

with a scaper a sapape, i you pree (or

i yo oget, as I .

Addng ogee blocksto the sde rals1 ip the ou ogee bocks to with 5 i orthe heaboa bocks a i. or the oot

boa bocks. Fi boars that match we

coor a grai so the jot betwee the

bocks a the ra i s't obvous. Aso make

sure the e ga o the bock matches that

o the rai (see Grai Orietatio o the Sieais" o p. 9).

o the leg with a

gouge, inih upthe cut with a kew

chie

Photo F: Sa nd the trantion rom quare to round u ing a anding

dowe o you don't bur the edge anding by hand.

H K E R - T Y B E

2 Jon the boom edge of the sock straght

and smooh.

3 Ct he headboard bocks to 1 n. ong


56/196

PhotoG:

Burnish the leg with a handful of clean shavings after al the

sanding is done.

Photo H: Trimmingthe cheeks of the

tenons to fit the

mortises is easy with

a shoulder p lane.

Note that you cut

across the g rain

4 8 S H A K R - S T Y L E B E D

g

and he ooboard bocks to 0 n. ong.

hs leaves 1 n. extra: /4 n. for wase and14 n. or the enon.

4. ay ot he ogee shape on each bock and

bandsaw to shape Smooh he rogh edges

wth spokeshaves, scrapers, and sandpaper

5 Lne p the blocks wth the ends o he

ras and glue hem n pace usng caus made

rom the cutoffs (see h I on p 50).

6 C t he ral ends square and to ther in

shed length o 76 n after the gle dres

Cutting the stub tenonsThe sde ras se a short tenon nstead o wo

dowes to agn and renorce he ra-oleg

jont agans tws and shear forces


57/196

Photo : t' eay to

camp the haped

bock to the ide

i i


58/196

Photo J Both othee wooden bot

hoe cover ook

good with the bed.

Chooe o yo ure.

O H A K R T Y B E

rai i you ue cau

made rom cuto

et over rom mak

ng the bock

(panted darker o

better viibiity)

CLEAT DETAILS


59/196

e srews old the l ea to the ottom o e rai l shoul d e spaed 4" a part.

The dowel p s sou ld e spaed 5 apart .

END VIEW

.' overhang

1 "

SIDE VIEW

%"

Dowel pin ;'x 1 W'

f % " j r % jI 2;'-

Cleat

9 Dve screws nto the hoes one at a tme

checkng to be sue the al and cleat stay

poperly algned.

Making the bolt hole

coversYou can purchase bolt hole covers for thsbed or you can make your own out o wood

The wood ones ae smple to make and ae

more tradtona. You can ethe make P/-n.

y 1/n. rectangles o /-n.thck stock, or

cut out ovals (see J)

1 To make eter square o ound bolt ole

coves cut them to sze sand the edgessmooth then chame the outsde ace wth a

plane or sandpape.

2 Dll %n-damete hoes n the tops

and I-n. or 5n pot holes n the egs

Dowel pins

Piot holes forscrews

about 3/8 n. aove the top o the counterbored

bolt hoe.

3. Secure te coves w th #6 by -n. round

head rass scews

Makng the slatsAll tat emans s makng the ed sats andinsng the ed

1 Make the 3/-n.t hck n.wde e d sats

out o mape o get the exact length you

shoud assemble the bed ist and measure the

dstance nsde the rals.

2. Notch the ends on the bandsaw wth a

oute o uprght on the tae saw asdescrbed n A Jg [or Notchng Bed Slats" on

p 4. Drop each sat nto pace over the

dowe pns then lt te mattess nto place.

Ceat

H K E R - T Y L E B 5 1


60/196


61/196

PENCIL- P OST BED

B

eds with four tall posts at the

corners have been around

since the Middle Ages In the early his

tory of the bed, the posts held heavy

drapes that both created a more private

space and helped retain some heat in

otherwise poorly heated rooms The

Pencil-Post Bed is one of many varia

tions of this form and lightens it up

considerably What I like so much

about this particular type of bed is the

distilled simplicity

his is the only bed in the book that

can be built almost entirely without

glue There arent any glued joints You

may have to glue up the headboard

plank out of narrower boards, but once

that's done, you can pretty much put

the glue bottle away

On all of the other beds, the head-

board and footboard are assemblies. On

the PencilPost Bed, each of the posts

and rails remains separate. All these

parts are held together with bolts Dry

tenons hold the headboard in place on

the posts, and the bolted connections

between the headboard rail and the

posts capture the headboard securely in

place Why is this? The bed has to dis-

assemble nto single parts o r it would

be almost impossible to move out of

any one room into another. f you

glued the headboard up in your shop,

you might have to sleep in your shop

5 3

PenciPost BedAS HE RE SN ' MU H I E N i n t s ed, t s exp loded iew is e l l y n


62/196

n oled iew. N oe ow t e ots for t e hed ord n d ootod i s e off

set om he s de r l ots The ed od p nk i s tenoned o he hedord

posts he tenons js hod he ed ord pos t o Te ols od in g te

posts to te r s keep the hedord secre y p ce .

Pot

Headoard plak

eadoard rai l

de rai

5 4 P E N L P O T B E

Bolt hoe

ootoard rail

H E A D B O A R D

View i s from ins de bed

F O O T B O A R D

Vew is o outsd e ed


63/196

2"8"

2"

28 "

1

80"

1V"(top opost)

1 7 "

' countrborfor bd

5% 5W

1 2"

'732" hol

2"

1

f

W'

C U T L I S T F O R P E N C I L - P O S T B E D

H e a d b o a r d a n d F o o t b o a d

4 Posts

2 Headboard and footboard rails

Headboard pank

4 Finial s (turning banks)

2 ester rails (head and foot)

2 Tester rail s (sde)

S i d e R a i l s

2 Side ras

H a r d w a r e

8 Traditiona bed bots with nuts

6 Mattress hangers and screws

4 Dowel pns

8 Brass bolt hoe covers and screws

2% in. 2% n x 80 n

% in 5 n. 60Y in.

n 1 7 n 6 1 n

1% n 1 % i n. 4% in

o in . 1 Y' n. 63Y n

o in . Y' in. 83' 7 n

% i n 5 n x 81 n

n 2 n

These dimensions are for a queen-size bed wit a box spring an d mattress. You may have to adjst yordimensions to sit te bed sze, the mattress size or any differences in wood dimensions.

P C I - P O S T B E D 5 5

UG E EE


64/196

P O S T DE T A IL S

e posts ae te s ge ost copex pat to ake.u a e jo ie ry te posts eoe yo ape te, a

yo save ay eaaces .

Mortiss forhaboar 2" 1 "p (only inth haboa poss

80"

' -8"2"

28"T

18

'

5 P E N L P O B E

" countr

bor" p

ransiion fomstraight scton otapr octagon

mortis7/3"p

TH PNCIPOS BD beas downnto a oeton of nne ajo pats:fou posts ou as and the headboad. hebox spng s suppoted by ast-on baetssewed to the sde als You an add ethenals o a teste to deta the tops of theposts. he wo pogesses o posts to asto the headboad sne the fnshed posts ae

helpul to dll the als auatey and theheadboad densons should oe fo atest-t o the headboad posts and al

E OSTS

Mlng the postsAs you ght expet ost of the wo onthe Pen-Post Bed goes nto the posts. hebas llng otsng and shapng of theposts aounts o alost half of ths poe t.otunatey the wo s nteestng andewadng.

Ml up sto o fou posts 2% n. squaeand 80 n long y to nd 12 sto fo theposts. f you ant glue the u p fo 8sto. wo ayes of 6 sto do not ae2/ n th one jonted and paned.

Motsing and dillingthe posts1 oo at the posts and dede whee youwant the on the bed Ma the ntendedposton o eah post on the botto lose to

IJyu glue u badsJ the sts t tut eces w th s mla gan tgethe b th n

tems j aeaance and entatn Glungtgethe quateed andatsawn bads s an

nvtatn t tuble late And t t kee theseam between the layes centeed n the sts

LAY I N G O U T TA P E R S O N T H E P O S T B L A N K S

apes give e oss ef io a igess eye aso easy o ct


65/196

B post bak

Straght scton

1 Mark out th finish imn sons on th top a bottom of th posts. orth top st th marking gaug to

o th bottom st it to

2 M ar k th li mits of th straight sctios with a pcil a a squar Thyrlocat from 1 to 8 " up from th bottom of ach post.3 Draw straght lins btw th conrs of th straight sctio a th

finish imnsion marks o th uppr a lowr sctions of ach postbut only on o fac of ach post f you mark th taprs on ajacntfacs bfor cutting th fst two taprs you l just cut off th marks forth sco fac whn you basaw th first.

he eer hs way he marks wll survvehe shapg proess.2 Lay ou e ra morse oaos o allour poss. ey are al eered o e possad oaed bewee 2/ . ad 7/ . uprom he booms (see Pos Deals")

3 . Rou he morses wh a puge rouer. sragh b ad ee he poss arewde eough o rou whou ay addoalsuppor Make he u wo passes oe romea sde o he pos. Mar ou e loaos or he bol holes,saggerg hem so hey do o erseMake sure you s agger hem ossely whlow oes or he sde rals ad hgh oes or

he headboard ad ooboard or ve versa.

5 Drll e . ouerbores or he bolheads he ousde aes o he poss abou/ deep

Drll e -. or -. bol oes abouhaway rough e pos rom he ousde.7 Measure ad mark he loaos o he

hoes o he sde aes o he poss ( emorses) ad drl ba o mee e bolholes. O ourse you ould also drl beoremorsg ad avod s roube You ouldalso do a o e drlg aer youve ue poss o shape (as you see he poographs) bu oly you orge o do ow(as dd)

Markig gaug lins

ip Set u the

ute to ut o the

Ja sde oj the ost

Jm the Jee. hs

way J the Jee

sl s Jom the ost

whe utg the

mstake a be ut

away o the ext

ass

P E N L P O S T B E 5 7

Post-Taerng Jigsou ca use ese j igs ee w a badsaw o w a ae saw a as eogade e ig o cu oug e comied ickess o e j ig ad e pos Hols for clamps


66/196

ade e ig o cu oug e comied ickess o e j ig ad e pos Hols for clamps(Tuts rcss

urath

V

Sco cut si

Hos for camps(Tuts rcss

urath

B U I L D I N G T H E J I G S

1 O o si of a pic of plywoo about 8" wi a 8' logpostio a post blak so that th wg-shap pic you'll b cuttig off xactly ovrhags th g

Draw a li o th plywoo whr th post rsts This s th layout

li for th gui strips o th "frst cut" si Attach th gustrips alog ths is3. Chck th gui strp locatios by tracig th jg g oto a post

blak o whch th first tapr has b alray cut Ajust ascssary

4. Attach som typ of clampi g mc haism to kp th posts scururig th cut ou coul us quick-ras camps but som simp -shap bloc ks from som scraps of woo bolts a Tutsaso work vry wl5. Aftr you cut th first tapr rpat th abov procss o t h othr

si of th jg for th "sco cut" O this s th gu stripsrgistr agaist th facs that wr tapr first a cut taprs o

th opposit si

5 8 P E N L - P O B E

96"

F O R U P P E R TA P E R8 "

ol for VB

clamps

rcss(Tuts

urath

6W'

irst cutsi

61W'

Sco

F L U S H T R I M M I N G G U I D EF O R T H E B AN D S A

e edge e per ig j ig ides


67/196

gis e se f t s gu de des eere wit e cttg

Bandsaw bad

to "thick

Guid clampdo badsaw tabl(ot shown

F O R L O E R TA P E R

8%

8

2' 203

1 1 " 1 2 %

First cut Scondsd cut sid

Cutting te taperson te postshee ae several good ways o tape the oursdes of the posts u y eye on te andsawor use a g on te andsaw or on he talesaw eehand utng on the andsaw s sple ut reques prety good tenque for astraght u over su a ong dsane e jgalernatves ae oe nvolved ut guaaneeresults.

1 . Mak ou the tapes on the posts seeayng Ou apers on te P ost Banks" onp 52 Make wo taperng jgs one for he upperaper and one for the ower aper (see Postapeng gs ) he jgs work equaly well onethe the andsaw o te tae saw

3. On the andsaw te gs rde aganst hefush-trng gude. Set the trng gde

o ut n shy o te taper layou nes see A

Photo A: he hod

down camp i n the

oreground i a

bock and a bot

threaded nto a

receed -nut on

the bottom o

the jig

P E N L P O T B E 5 9

ip You er

smer ees oj

woo o he oer

sJey bu o' ry


68/196

Photo B: On a table aw with a bade that can be aied to at eat

3% in., the tapering jig work very we. Camp a piece o pywood on

the other id e o the ba de to prevent the wedgehaped cuto om

dropping though the throat pate.

0 P E N P O S T B E

wh 7-J.-ooss I eous

you' ever e

he e rh

On te tabe saw se te p fene o nwde tan e pywood apeng jg eopposte edge of te jg des agans te pfene as te sawbade uts e pos aostus wt e g (see ) 5. Cu e apes to e outsde of te nes onete e bandsaw o te table saw eavngenoug oo o lean up e uts W bogs you u tapes on two adjaent faes wt

e post on e s u sde of te jg tensw ove to e seond ut sde fo eeanng two faes Save e uo ffs fo e apeng of teuppe pat of e postyoul need tewen utng te otses fo te eadboadplan. Clean up e apeed faes wt a andpane o by sandng y o avod utng ntote stagt seon.

Gvng the posts eght sdesWen tapeed te poss ae ony alf donee apes sll need o be ut nto an otagona pofe

1 . ay out e edges of fou new faes along

te apeed poons of e posts (see woOagon ayout Meods.2 If you use e layou g pate w afew es on soe saps of %-n wood It'snot e easest g to use beause te pontstend to wande

3. Wen onden ap te pos seueyso you an use wo ands on e jg andsbe te otagon lnes.

Two Octagon Layout MethodsYou ca n lay ou he octago oe o two ways . he i rst i s by dete

mn ng the octago pof le and d awing the l es wih a sa ig htedge.


69/196

The second ena i l s b i l d g a s i mp e j i g .

D R AW I N G A N O C TA G O N P R O F I L E

he distance from a corner to the center of the squae whentansferred to the sides of the squae defines the corners of the

octagon

1 Draw three different-sie squares: one that's the same dimensions as th e very top of the post one of the bottom and onethe size of the straight section (2% by 2%") that you will use atthe top and bottom of ths section

2. Draw the two diagon as to find the center of each square3. Set a compass to the distance from on e of the corners to the

cente of the square4 With the compass point in the corne of the square, mak the

sides of the square Repeat this process fom the other cornersand you'll locate the points where the octagon sides meet

5

Transfe the dmensons fom the drawn ocagons to the facesof he posts

6 Con nect the points on the post with a straightedge to createthe edges of the octagonal facets

O C TAG O N LAYO U T J I G

his jg scrbes ines that wil defne the edges of the octagon all aong the post

he dowels ride along theedges of the post andthe brads scribe theedges of the octagon

%"-1 "

Use an octagon dawn tothe sze of the staightsecton of the post to layout the location of thebads and dowels

Brad tips fled to sharppoints stick out 2'

P E N C I L - P O S T B E D 6 1

A Jig for Cutting Tapered OctagonsT i j g ot he ot when bandawing he angled acet o make an octago.


70/196

C L A M P

"

3

T O P V I E

8"

1 raius 2Y 1 Y

1V

1

Start to cut the octagon ide at the end o the pot. Startng atthe quare ection wil caue problem.

2 P E N - P O S T B E

2%"

f

7Y

-

20"

M AK I N G A N D U S I N G T H E J I G

1 . ay out th proi o a post (with a at straightsctio i th ctr o a pic o %" plywoo that's SY w a 8" og Draw i actrli

2. Cut away a smooth th jig to th proil li o

th post as show i th rawg ou'll wa t tomak your ig th mirror imag o mi i youbasaw's throat is o th lt si (op o thright3. Mak a attach a clamp at th bottom a a

support ar th rot to hol th post scurly4 Us th ig with th sam lush-trimmig gui

you us or th oursi tapr ig5. Th ig works bttr wh you cut rom a

tha wh you try to cut rom th straght sctio That's why you cut o ly o s o thuppr a lowr proils o th jg

6 Rotat th post a cut th xt acts Rpatutil th octagos ar compt


71/196


72/196

Photo D: The author clamped the wedgeshaped cutoffs from the

tapering operation (darkened for better visibility in the photograph)

on either side of the post to provide a straight reference edge forrouting the headboard mortises.

Photo C: It taes a twisting motion with

the sandpaper-wrapped dowel to clean upthe curved transition area between the

square joinery block and the octagonal post

effectively.

with a router 1 in deep (see h D) You

can also dri ou t the waste wood and chop

the mortises by hand

4 Chisel the ends o the mortises square andchamer the mortise edges very lightl

MAKING THE RAILS

Miling the rail stock1 . Mill rail stock or the side, headboard, and

ootboard rails, and cut them to length (see

Rail Details")

2 Ct the tenons on the ends o the rails on

the table saw with a dado blade or with a

router sing a /in rabbeting bit To spport

the roter when cutting the narrow sides,

camp a pair of rails together (see ht E)

3. Rot the wider faces to complete the

tenons (see h F.

Drilling for the boltshe easiest way to dril the bed bolt holes in

the ends o the rails is to use the hoes in the

posts as a drilling guide

1 Clamp a headboard or ootboard rai

pright in a bench vise and hold the appro-

priate post in place. Make sure you'vematched up the correct post with the rail

R AI L D E TAI LS

Tip: When ruting

tenons using a

rabbeting bit, stop

a li ttl e short of the

end of the board


73/196

Rcsss for mattrss hang rs(si ails ony)

Haboar an footboar rais ar0X" (59X" btwn tnons).

Phoo E: To make he eos o he side rais, camp he

wo rai ls ogeher ad ou a rabbe o he op a dboom.

end of the boardand chisel away the

rest. This prevents

cutting the rabbet

around the coer

by mistake.

Phoo F Rou he rabbes o he sides of he rais oe a

a ime. Be vey carefu o o ru he bearig aoud heed of he eo whe sarig or fiishig he cu.

P E L P O B E 6 5

oure dling. Snce he hoes are oset, ou

don wan to drl a ra ofse the wrong wa

2 Drill down through the hole n he post as

fa as ou can into the rail (see p G)

Youl have t o dr deepe once ou remove

the post om the end o the ail o dr


74/196

Photo

G:

Dri ing the hoe for the bed bot in the end of the rai is

best done by using the post itsef as a dri l gui de. Hod the post

secuey in pace whie you dril

6 6 P E N I L - P O S T B E

the post om the end o the ail o dr

between 3 in and 4 in. deep, uness ou

have a ve long tws dri to do he job a

a once.

3. o dll hoes in he onge sde rails, clamp

them in he bench vse a oughl a 45 degee

ange. Othewse, oul have to clmb up on a

stepadder or on top of the bench tsef to dri

the hoe.

Embedding the bed boltnuts in the raishough tadional and elegan, capurng he

nut fo the bed bolt inside the ail is a ot of

wo an d strctl an option You coud use

an o the easie techniques described n the

othe proecs n this boo. Bu ths echnque

leaves a compleel hidden nut and eases bedassemb

1 Rout a recessbasical a in. b n.

b 1 -in.-deep mortiseon the nsde face o

the side ail (see Setting a Capured Nu n

he Rail").

2 Mi some enon soc abou 12 n. long,

and round ove he edges o mach the ounded

ends of he mose (wihout gue)3. Insert one end of the tenon soc all he

wa down into he mortse

nsert a bed bol no the hole in the end of

he ral, and ap i to mar he bol s location

on the tenon soc.

5. Remove the tenon stoc and a out he

location o the nu, cenered aound he bolts

mar.

Dril out he wase and caeul chse the

hole square so the nu is snugl

7 Put he nu in the square hole in he

enon soc and glue he soc n pace (see

p H)

head the bot onto he nut befoe the

gue dres o be sue t wos.

9 Afer he gue des cut he enon ush

wih the inside ral Al that wi show s alitle patch of end gran.

S E TT I N G A CA P TU R E D N U T I N T H E R A I L

Embeddg a n eo stock tat s into a roted ecess grealy s impl if ies he

process o embeddg a nu t the ra l .


75/196

Rail

Adding the mattresshangersTo sppor the matress you can se special

casiron matress hangers, avaiabe rom some

of the speci alty hardware cataogs ised in

Sources on p. 83 Yo can also se fl

length angle iron or Vin. by V2-in. by V2-in.

Lshaped auminum angle stock. You could

also se wooden cleas as in he First Bed proj

ect, bt the meal brackes le yo hide abou

1 in more o the box spring inside the rais.

1 . Rout recesses or the casiron mattress

hangers in he side rails so the box spring

wont snag on he edges of he hardware. If

yo eave an exra in. space between he

rails, his won't be necessar

2. Screw the hangers into place afer al o thefinishing for he bed has been don e.

Tenon st ock is fush-cutafter t's properly alignedand the glue dies.

Bolt ho,

Photo H: A captued

nut is ready to be

inseted into themortse in the sde

rai l . When gued n

pace and cut fush

against the a, it

makes an elegant

joint

Tip Dont use sm

le hardware store

bracets to suort

a box srng

theyre not stng

AING TEHEADOARD

Glung up te eadboadf yo ave a sige board wde eog for te

2. Jo te edges careflly ad gle togeerLet te gledp pla st for at least 24 ors,ad te smoo it3. Assemble e wo eadboard posts wit teeadboard ra to get a exac egt for teeadboarddo't s rey o te dimesos


76/196

y genough

y g geadboard wtot gg it p, te sip ostep 3. If o, yol eed to ge oe p

1 . Coose te boards ta will mae p eeadboard, mag sre ey mac for coorad grai A board tat is al f te ecessarywd b twce te egt is say a good

coice. at way yo ca ct i i af adave two boards very smilar caracer

Phoo Rou he enon a nd he ransion curve of he back of he

headboad. Do hs before you shape he headboard so he oue

fence can regiser agains a ong enon edge

8 P E N P O T B E

y e drawigs for ts. Measre betwee e lower morses o teposs e add e dept of te mortises tocome p wi a al legt for te eadboard. Oly te sold yo crossc teeadboard o eg

Cuttng te tenonse eos o e eadboard are ot typicaleos i a tere are o solders Becasee eadboard is tcer ta te mortsesare wide yo do eed to ct te edges ofte eadboard dow o t i te mortisesAltog a sraig taper ca wor, recommed a crved rasiio.

1 . Ct a /- -og rabbet across bo edsof e bac of te eadboard, eavg jst overe desired eo tcess. Ts ca be doeo te table saw or by sg a roter ad astraig bt wt a axary fece ataced.2 Draw te sape of e trasto crve oa edge o gde yor cts.3.Wt a corebox bt (a covig bi wiot apot i e roter, mae a mber of passes

adstg bot e fece ad te bt eig towaste away as mc wood as possbe (see I) crape ad sad e crve wt sadpaperwrapped arod a i. -dameer dowel torefie a

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