Furnishing the bedroom was one of my major woodworking goals.
Before I started with this bed, it was furnished with a metal frame for the box spring and a dresser
from my wife's childhood. When I first started woodworking I thought I might
not ever be good enough to build real quality furniture. I didn't know it
was an attainable goal Most of the projects up to this point have been
either workshop tools or children's furniture that would be outgrown someday.
In the Fall of 2003 I decided that I was ready to take the plunge and get
started on my bedroom.
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The four posts are constructed with 3/4" stock and lock
miter joints. I spent a lot of time practicing lock miter joints and
I was held down by the fact that my router bit didn't come with any
instructions. It's fairly difficult to set up and you need a
router table but once you get the hang of it,
it's a useful and strong joint.
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I got this clamping tip on www.woodnet.net.
It's difficult to clamp every inch of a 50" pole. I went to a local
bicycle repair shop and asked for a free inner tube that they had replaced.
I clamped one end to the work the tightly wrapped the piece with the
tube. Next, I used a 6" C-clamp to pull the work together, no normal
human can get the clamping pressure with his bare hands. Once it was
pulled together the inner tube held it in place. The process was to
squeeze, move down a few inches, squeeze, etc. I repeated this for
each side then made a final pass looking for imperfections.
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I used an old #4 Stanley hand plane for the surfacing. That's not a
gap in the joint, it's a shadow line. This kind of joint allows you
to have nice face grain that wraps around on every side. But you need
to shift the wood a bit to compensate for the 1/8" kerf. Make it long
and cut it to length.
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Now that the posts are assembled I worked on the curved
stiles. I marked out the curves and the location of the mortises and
went to the bandsaw. I sanded the curved waste material and used it
as my sanding block. The sawhorses kept moving around while I was
sanding the piece so my daughter was more than happy to help me out by
holding it down.
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Here's another shot of her holding down the sawhorse.

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I used my mortise marking gauge to mark two of the edges
for the
mortises.
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Next, I used my saddle square to mark the other two edges.
I marked the left and right sides of the edges before I cut it out with the
bandsaw so this is really just to give me a line to register the chisel
in.
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You can't really see it but I used a 6" rule and a sharp
pencil to mark the center of the mortise. Then I used an awl to give
me a little hole to register the auger in.
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I learned during my practice mortises that I wasn't tall
enough to use the auger on top of my bench without a stand. I had
some cedar landscaping timber in the garage so I made this stand. The
picture doesn't do it justice but I really like the way it turned out.
It's sort of rustic and the rails are book matched. I used dowels
for the joinery. It's sized to slide under the bench for storage.
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Colin is giving the old auger a try. On a side note,
if you ever lack humility just mount a lighted magnifying fixture like you
see there. You'll find flaws you never knew you had. :-)
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I think this is my favorite part. It's satisfying to
remove 90% of the wood with my brace and bit.
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Ahhhh, the fruits of my labor. Now it's time to break
out the chisels and square up these holes.
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My technique is getting pretty good. This picture shows
me using a bench chisel but I did the bulk of the removal with a mortising
chisel. The mortising chisel is nice because it doesn't have a wedge
on the side of the chisel to drive the cutting edge away from the circle
created by the drill bit. I timed myself, it takes about 2 minutes and
15 seconds for me to square up an auger hole into a mortise.
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After I cut about 50 5/8"x 5/8" stiles on the table saw I
prepared the surface. They were so narrow that my #4 hand plane was
kind of "tippy". My hand scraper didn't leave a really great surface
but my Veritas cabinet scraper did a great job. On the other hand, I
made about 50 of these stiles and they each have 4 faces. 200 sides
will have nearly anybody thinking that maybe a drum sander would be kind of
nice. :-)
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I used three or four passes from 220 grit sandpaper to take
the sharpness off of the edges. I just pinched it so that it didn't
touch the face of the work. Somewhere out there a purist is
complaining that sandpaper touched my project. However, I liked the
effect it had.
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When they are stacked like this the stiles and rails really
don't look like 50 hours worth of effort. :-)
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I used some poplar scraps to create 1 1/2" x 1 1/2" x 10"
solid centers. After I ran out of poplar I used Douglas fir 2x4s cut
to size. I wanted a soft wood so that if it had to compress it could.
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Next I glued up the sides and pushed it into the legs/posts. While I'm
not using one in the picture it took a couple of light mallet blows to get
the inserts to fit in the legs. I was able to get a pretty good fit by
cutting it a little bit large then planing it to size.
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Here I go again, removing the waste for another mortise.
I think I can safely add mortise and tenon joinery to my woodworking resume.
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Here's a finished mortise. I know the bottom isn't
flat. Don't tell anybody. :-) I've put so much work into this
bed that I really don't want to mess anything up at this stage. I take
a lot of time before each joint.
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My next step was to do a dry fit and then measure every
stile and cut it to length. While I was at it, I picked the nicest
face of each stile and numbered it. I made extra stiles so that I
could reject some if they didn't meet quality control.
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The headboard glue up was tough, my wife helped me out with
the entire operation. First I dry fitted all the stiles. In the
process I broke one and had to trim another. After that was done I
just measured to see if it would fit the legs. It was fine.
This glue up would have been a nightmare without my wife's
help. We used 4' Cabinet Master's clamps to crank everything in place
while putting the stiles in the rails. Next, we brought the legs
over and used 10' pipe clamps to hold everything together. Most of my projects are pretty large so my
10' clamps come in handy more often that I thought they would. Another
tip, white Elmer's glue is the same thing as Yellow Elmer's glue (which I
normally use) except that it doesn't have a chemical to speed up drying.
If I need extra open time on a project I use white glue.
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I'm measuring for a dry fit while Hope is sweeping up.
Like most four year olds, she generates more dust and enthusiasm than
results. I found that a folding ruler with a brass extension is the
ideal tool for measuring inside something. My tape measure kept
folding over and I had to add an 1/8" to the measurement to account for the
metal tip thing. Yuck.
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The glue up for the footboard was intense too. Again,
my wife gave me a hand.
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I'm getting closer. Here's the headboard and footboard
all glued up.
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I made a template for the corbels and used it to mark the
outline. Next, I cut it proud of the line at the bandsaw. I'd
use a frame saw in keeping with my Neanderthal style but I'm still getting
the hang of cutting well with one. Next I attached the template to the
piece and trimmed it to size at my router table
with a pattern trimming bit. I don't have a spokeshave so the router
table was the only option. They aren't trimmed and their surfaces
aren't prepared yet in this picture.
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The spindle glue-up caused both the headboard and the
footboard to bow a bit. I thought I clamped the middle properly but I
guess I didn't. I used a piece of string to mark my desired level and
then I started planing.
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Here's a shot of the #7 I used to level it off.
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This is the mortise for the
bed rail hardware. The hardware fits in the groove pretty snugly, I'm
happy with the way it came out. I left wood above the hardware (it's
upside down in this picture) because that's the direction that force will be
applied to it when people are in the bed.
That thing sticking out is a 3/8" dowel. It's driven
in behind the bed rail fastener because screws don't hold in end grain very
well. The dowel should provide a better gripping surface for the
hardware. I trimmed the extra dowel off after the picture of course.
Also, it only shows on the bottom, it's not a through dowel.
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These dowels serve two purposes. First, they provide
alignment for the top of the headboard. Second, they provide a better
gluing surface than the end grain for holding the board in place. One
of my boards had a 1/4" twist over 6' that I wanted to hold down
mechanically. I'm slightly concerned about how they'll react to wood
movement but they are only 2" apart so I expect it to work out ok. One
dowel would have handled more wood movement but it wouldn't have worked out
the twist.
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This is the glue-up for the headboard. I've been
building a lot of large projects lately so I've gathered a pair of 6' (and
10') clamps. I didn't realize how often I'd be using them.
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This is the glue-up for the footboard. As Norm would
say, "Let's let this cook overnight." :-)
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These are the rails that support the mattress. The
plans called for simply screwing them in but I thought a tongue and groove
joint would be stronger and nicer. Also, I had gotten this far without
any metal in the project so I didn't want to break my stride. :-)
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Here are the rails getting mated to the slat supports via
tongue and groove joint.
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This is the only metal in the project. It's the
bed rail fastening hardware. It was slightly too long to fit my
bed rails so I had to grind about 1/8" of length from both sides. Of
course, the side that fit into the leg didn't need any modification.
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I have a simple crosscut sled with a purpleheart fence that
I use for cutting panels or for long crosscuts like this one. This is
the support for under the box spring.
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These are the completed box spring supports. I wanted
to do something to prevent sagging. I considered putting a leg in the
middle of each rail but I didn't want anything that might not last and I
didn't have any ideas for something that would look nice. I ended up
going with a T system. It's kind of like an I beam but there is only
one horizontal section. They are very strong. I used sassafras
for these rails because I didn't want to waste expensive cherry on a section
of the bed that will never be seen. Also, sassafras is a stronger
wood.
The reason that it's wet in this picture is that I wiped
away the excess glue with a wet rag. I have no plans to apply a finish
to the supporting slats so a wet rag should be fine.
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Here she is right before her I start on the finish.
All the surfaces are planed and scraped and it's ready to go.
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The first step in finishing it was to apply a
coat of Watco Danish oil. Next, I mixed a 2 lb cut of blond shellac,
seen sitting on the router table, and padded on 4 coats, sanding with 320
between each coat. After the final coat I'll rub it down with 0000
steel wool and wiped off any dust.
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At last, the bed is finished. Here's a picture without
the mattress.
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Here's another picture without the mattress.
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Now with the mattress in place.
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For some reason it looks like the footboard is lighter on
the left than it is on the right. In real life, it looks nice and
even.
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A few months after I built this bed I finished a
pair of matching nightstands. It's
hard to see the far nightstand but there is a matching piece on each side of
the bed.
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