DIY Network

	WOODWORKING Index
	Antiques Bedroom Seating Chests Decorative-Accent Furnishings Shelves & Cabinets Tables Products Woodworking Shop Other

BEST OF WOODWORKING

Mold Quiz
Home Safety
Room Planner
Pet Care Guide
Weekend Projects
DIY to the Rescue
Sparkling Solutions
Organize Your Home
Ultimate Media Room
Picture Perfect Parties
Queen of Clean

SPONSOR LINKS

Making and Attaching Quilting

The Eco-Headboard is coming together.

From "Freeform Furniture"
episode DFFF-108

In this second segment host Amy Devers makes the quilt for the headboard and attaches it to the panel.

Host Amy Devers does the quilting for the Eco-Headboard.

Materials:

Clear vinyl
3/4" pre-finished maple plywood
1/2" unfinished plywood
T-nuts
2" foam
Bonded batting
Muslin
Staples
Steel U-channel
Recycled T-shirts
1-1/2" stainless steel tube
1/8" round-over bit
Forstner bit
Wax pencil
Ruler
Heavy-duty thread
Spray adhesive
Clean rags
Spray paint
Tape measure
Welding gloves
Ear protection
Safety glasses
Face shield
Cutting fluid
Welding jacket
Welding mask
Filler rod

Tools:

Staple gun
Laminate trimmer
Clamps
Awl
Drill
Drill press
Hammer
Shears
Razor knife
Sewing machine
Respirator
Chop saw
Ratchet
TIG welder
Grinder
Hand sander

Figure A

Figure B

Figure C

Figure D

Figure E

Figure F

Figure G

Making and Attaching Quilt

With a wax pencil, lay out a grid on the vinyl (figure A) and follow it on the sewing machine.
Cut the T-shirts in half creating a front half and a back half.
Lay the T-shirts out on top of the muslin (figure B). Pick out complimentary colors and patterns.
Take the vinyl, with the grid facing up, and lay it over the T-shirts.
In order to get everything in the sewing machine, roll it up.
Slide the roll into the machine with the center line under the needle. Sew down the line and work your way out on either side of the center stitch line. (figure C).
Sew the sandwich lengthwise. Use a basic straight stitch and sew with heavy-duty thread.
Upholster the plywood panel. Use a spray adhesive to attach the foam to the panel.
Safety Tip: When using spray adhesive, you want to work in a well ventilated area and you should probably wear a respirator.
After the foam is attached, drape batting over the panel and then stretch muslin over the whole thing and staple it in place.
Spray an even coat on the foam and the surface of the plywood. Let it set for a few minutes until it is tacky.
Lay the foam on the plywood with the beveled edge facing down.
Press the foam firmly onto the plywood (figure D).
With the muslin on the table, unroll the batting and lay the foam panel on the batting, foam side down (figure E). Starting in the middle, wrap the muslin over the edge of the panel and secure it with a few staples.
It is important to anchor the muslin in the center first and then the corners. Move to the opposite side and repeat the process.
Next, go to the end of the panel and staple the muslin down. Then go to the other end and do the same thing.
Go back to the top edge and put another staple in. Repeat this process making sure to pull the muslin tight before stapling it down (figure F).
Check the front of the panel every so often to make sure the foam isn't bunching up. If it is bunching up, remove the staple and adjust the foam.
Note:It is important to stretch the fabric tight so that there is no space between it, the foam and the other elements. You want all the elements to form a solid unit.
Stapling at each stage of the process is also critical because a single loose area of fabric can result in sagging.
Once you have stapled all the way around, take the shears and trim off the excess muslin and batting (figure G).
Now you are ready for the vinyl sandwich, lay it face down on the table, tip the form on over it, smooth taut over the form, and wrap it around the edges and staple it on the underside just like on muslin.
Take a clean cloth and polish off the marks.