Cut list
| Part | Qty | T × W × L | Material | ✓ |
|---|
| Inner Rail | 2 | 3/4" × 3" × 46" | — | ☐ |
| Inner Stile | 2 | 3/4" × 3" × 30" | — | ☐ |
| Short Brace | 2 | 3/4" × 3" × 25" | — | ☐ |
| Long Brace | 1 | 3/4" × 1" × 51" | — | ☐ |
| Upper Outer Rail | 1 | 1" × 3" × 53" | — | ☐ |
| Lower Outer Rail | 1 | 1" × 3" × 53" | — | ☐ |
| Leg | 2 | 1" × 5" × 57" | — | ☐ |
| Lower Cap | 1 | 3/4" × 3" × 66" | — | ☐ |
| Upper Cap | 1 | 1" × 5" × 68" | — | ☐ |
| Back Panel | 2 | 3/16" × 30" × 36" | — | ☐ |
Materials
| Item | Qty | ✓ |
|---|
| Board, 2x6 x 96" | 3 board | ☐ |
| Board, 2x4 x 96" | 1 board | ☐ |
| Board, 1x4 x 96" | 1 board | ☐ |
| Board, 1x4 x 72" | 1 board | ☐ |
| Beadboard plywood, 3/16" x 48" x 96" | 1 board | ☐ |
| 1 1/4" coarse-thread Kreg Pocket-Hole Screws | 48 each | ☐ |
| 2-1/2" coarse-thread Kreg Pocket-Hole Screws | 8 each | ☐ |
| 1-1/4" wood screws | 6 each | ☐ |
| 5/8" wood screws | 40 each | ☐ |
Overall cost: $$$. Lumber varies by region, species, and season, so we give a band rather than a figure.
Instructions
1. Cut the Inner Frame Parts
- Using the Cutting Diagram as a guide, cut two Inner Rails and two Inner Stiles to length from 1x4 boards.
- Also cut one Long Brace (D), mitering both ends at 23-1/2°. An easy way to get the length and angles exact for this is to temporarily line up the Stiles and Rails, then lay your board in place as the Long Brace will sit, and mark the ends. That will show you the correct length, as well as the correct angles—which should fall at 23 1/2°.
- Next, you can cut the two short braces two Short Braces. Keep your miter saw set at the same angle you just used for the Long Brace, and cut one end of each Short Brace.
- Then position then cut the other end to fit at 47°.
- Now Set your Kreg® Pocket-Hole Jig for 3/4"-thick material, and then drill pocket holes in each of the pieces, as shown.
- Sand the faces and edges of the pieces smooth, but don’t sand the ends.
2. Assemble the Inner Frame
- Now you can assemble the inner frame.
- First, lay all the pieces out to ensure that everything fits together tightly. Make sure the pocket holes in the Inner Rails and Inner Stiles are pointing outward, so you’ll be able to attach them to the outer frame later.
- Then assemble the rails and braces using 1-1/4" Kreg Pocket-Hole Screws. We built our headboard from pine, so we used coarse-thread screws.
3. Make the Legs and Outer Rails
- Using the Cutting Diagram as a guide, cut two one Upper Outer Rail and one Lower Outer Rail to length from 2x4 boards.
- Also cut two Legs to length from 1x6 boards. With Your Kreg® Pocket-Hole Jig still set up for 3/4"-thick material, drill a single pocket hole in the end of each Leg, as shown.
- Also drill pocket holes along one edge of the Upper Outer Rail, as shown. These will be used to attach the top cap assembly later.
- Then set your jig and bit for 1 1/2"-thick material, and drill pocket holes at the ends of both Outer Rails, as shown.
- Sand the faces and edges of these parts smooth, but don’t sand the ends.
Notch