Arched-Top Headboard

• Now you need to create a Top Filler.
• Once again, we cut ours from leftover plywood, as shown in the cutting diagram.
• Start by cutting an extra-wide piece from your remaining plywood.
• Then cut it to length.
• Lay the Top Filler in place between the Side Fillers, and then trace arc from the Headboard Face on to the Top Filler.
• Cut the arch with a jigsaw.

Spread glue on the Top Filler, and then clamp it in place, making sure the upper edge is even with the arched edge of the Headboard Face. Secure the Top Filler with 1 1/4" brads. After the glue dries, sand edges of the headboard assembly as necessary to ensure that you have a flat, even surface for the iron-on veneer edge banding that you’ll add next.

• Cut two pieces of 2"-wide iron-on veneer edge banding slightly longer than the sides of the headboard.
• Then cut one piece slightly longer than the arched top edge. Starting with the sides of the headboard, position the edge banding so it overlaps on both edges and at the ends.
• Apply the banding using an iron, according to the manufacturer’s directions. When the glue has cooled, trim the edging flush at the ends using a utility knife, and flush along the edges using an edge trimmer. After edging both sides, apply the edge banding to the arched top, as well. Lightly sand all of the veneer edges by hand, just enough to soften the sharp edges. It only takes a few strokes. Be careful so you don’t sand through the thin plywood face veneer.

• Cut two Table Tops, two Table Sides and two Table Bottoms from a 1 x 12 board, as shown in the cut diagram.
• Set your pocket hole jig for 3/4" material and drill pocket holes in the Table Tops and Table Sides as shown. Notice there are left side and right side parts so pay close attention to the pocket hole placement on these parts.

Attach the Table Tops to the Table Sides using 1 1/4" fine-threaded pocket screws. Make sure the Top and Side edges are flush with one another and the pocket holes face downward.

Attach the Table Bottoms to the Table Sides using 1 1/4" fine-threaded pocket screws. Again, align the edges and make sure the pocket holes face downward.

Attach the Tables to the Headboard Face where shown using 1 1/4" coarse-threaded pocket screws. Course-tread screws provide a stronger connection when attaching to plywood.

• Sand all of the edges and surfaces as needed.
• Then then thoroughly clean dust off of the headboard before applying your favorite finish. To create the washed finish shown here, we used a light blue color (Oatlands Dainty Blue from Valspar) and thinned it about 25% with water. We applied the paint with a foam roller, and then quickly wiped off the excess with rags while the paint was still wet.