Use reclaimed building materials to fashion a custom king-sized bed with vintage-style headboard.
About This Project
A home is the ultimate shelter from the storm, so what better way to enjoy a safe and sound sleep than snuggled in this custom-made hurricane-shutter bed? Need a place to store all those storm essentials? The space normally taken up by a box spring accommodates pullout under-bed storage.
Gather your supplies before you start this project.
Table and circular saw
15 ga. finish gun
Bit driver and bit set
Paintbrush and rollers
5 sheets 3/4” sanded plywood
1 sheet 3/4” prefinished plywood
2 sheets 1/2” sanded plywood
4 pairs of 24” side-mount 1/2” drawer slides
24' backband trim
1 1/4” 15 ga. finish nails
Type II wood glue
1” wood screws
4 drawer pulls
5 salvaged 16”-18” shutters or louvers
8 3” wood screws
32 1 1/4” wood screws
8' reclaimed 1x12 or similar
1 quart paint primer
1 gallon semi-gloss latex
Step 1: Cut Frame Sides
This frame needs to be slightly larger than a standard king-sized mattress (76" x 80") to allow space to tuck in sheets and covers. The inside dimensions of this frame will be 77" x 81" x 14". Start by cutting two 78 1/2" x 14" and two 82 1/2" x 14" frame sides from 3/4" sanded plywood and miter the corners at 45 degrees.
Step 2: Cut Drawer Openings and Fashion Gussets
Using a framing square, sketch two 19" x 8" openings for the drawers two inches from the bottom of the 82 1/2” frame sides. Position them 4 inches apart from the centerline and cut out the holes with a jig or circular saw. Next cut eight 4" x 4" x 3/4" gussets and build these into four sets of 4" x 4" x 1 1/2" gussets with wood glue and 15 ga. finish nails. On a flat and stable platform, join the four sides and corner gussets with 15 ga. finish nails and wood glue. Check for square and shim any of the gussets, if necessary. The corner gussets should be flush with the bottom of the frame.
Step 3: Cut and Attach Cross Boards
Cut four 77" x 10" cross boards from the 3/4" plywood and attach them across the frame with the face flush with the drawer openings on each side. Cut 24' of 1 1/2" ledger out of 3/4" plywood and attach with wood glue and finish nails 8 inches on center around the inside perimeter of the frame. The top of the ledger should be flush with the top of the cross boards. Next, trim the top of the 3/4" frame with bed mold or similar.
Step 4: Fashion and Attach Legs
Cut four 4" tall legs out of reclaimed 4" x 4" posts or similar. Bevel the edges for a finished look and attach each leg to a corner gusset with two 3" wood screws.
Step 5: Build Drawers
Cut the following pieces out of 1/2" plywood: eight 17" x 6", eight 24" x 6" and four 18" x 24". Using the 24" x 6" pieces as the sides and the 17" x 6" pieces as the fronts and backs, assemble the drawer boxes with wood glue and 15 ga. finish nails. The finished drawer should measure 18" x 24". Using the manufacturer's instructions, mount the drawer slides to the cross boards and the sides of the drawers. Make sure to allow at least 1/4" of clearance between the bottom of the drawer and the opening in the frame side.
Step 6: Build and Install Drawer Faces
Cut four 22" pieces of reclaimed 1x material. Center each face for an even vertical reveal when drawers are closed and attach with two 1 1/4" wood screws through the backside. Next, attach drawer pulls of choice.
Step 7: Source Shutters
Five 16-18" wide x 42" tall shutters will yield an 80” headboard, the ideal size for the bed frame. In this case, 18" reclaimed shutters were cut down to 16". Remove all hardware and, if required, trim equal amounts of material off each side of the shutter. Leave at least 1" on the vertical stiles so shutters don't fall apart.
Step 8: Trim Shutters to Size
Trim two shutters to 3'6" tall and three shutters to approximately 2'6" tall. Try to cut the shutter through the center rail if possible. If not, move the center rail up to give the base stability.
Step 9: Assemble Headboard
Place shutters face down on a flat work surface. Cut four approximately 2" x 3/4" binding strips and two 1" x 3/4" furring strips out of plywood and attach them to the seams and edges of the shutters respectively with 1 1/4” wood screws.
Step 10: Paint and Position Bed Frame
Paint the frame with one coat of primer and two coats of semigloss latex. When dry, move the frame into place, being careful not to rack it during transport. Next, cut two 40 3/8" x 76 3/4" pieces of 3/4" prefinished plywood and set them on top of the 1 1/2" ledgers and 10" cross boards.
Step 11: Install Headboard
Once the position of the bed is established against the wall, mark the outer edges and top of the frame on the wall with a pencil. Move the bed away from the wall and, using drywall anchors, mount the headboard on the wall. Be sure to position the anchors so that at least one fastener is attached to each furring and binding strip.
Step 12: Finish Project
Move the frame back against the wall, top the frame with the mattress of choice and enjoy a new hurricane-shutter bed.