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Beginning Process for Eco-Headboard

The project begins with work on the edges and back panel.

From "Freeform Furniture"
episode DFFF-108

Host Amy Devers starts on this unique headboard, made with recycled materials, by trimming the edges and working on the back panel, and then she cuts all the materials for the quilt.

Host Amy Devers makes a headboard using used t-shirts for the quilting.

And the end result is a unique embellishment to any bedroom!

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

Beginning the Process

Clamp the work piece down and cut the 1/8" round-over on the front edge of the 1/2" upholstery panel with the laminate trimmer (figure A).
Note: A laminate trimmer is a hand held router used for trimming laminate, but it can also be used for small routing jobs. The motor on the laminate trimmer runs faster than most routers because the bits are smaller in diameter.
Repeat the process on the 3/4" back panel.
With the 1/2" upholstery panel centered over the 3/4" back panel, mark where the T-nuts will go with an awl. Space six T-nuts evenly on each panel. The T-nuts will be placed 3" from the edge. Two nuts will be placed at either end, and the remaining two in the middle. To receive each T-nut, drill two different sized holes. Drill the larger hole with the forstner bit to the depth of 1/8" so that it can receive the flange of the T-nut. Then drill a smaller hole all the way through both panels to receive the barrel of the T-nut. After you drill the holes, separate the panels and tap the T-nuts into the holes (figure B) and then you are done.
Note: A T-nut is a threaded fastener with a barrel and prongs that make it easy to put steel thread into wood.
With the panels ready to go, prep the materials for upholstery. Muslin is an unbleached, plain weave cotton fabric. It is used to hold the batting and foam in place and really give the shape to the panel.
Clear vinyl comes in various thicknesses. Choose a pliable one that is appropriate for upholstery.
Tip: You can visit your local thrift stores and ask for their rejects. Just throw them in the washer on hot before you use them.
Foam comes in all degrees of thickness and firmness (figure C). A 2" medium density was used for this project.
Batting comes in cotton or polyester and bonded or loose.
Note: Bonded polyester was used on the show. You can get all of these items at an upholstery supplier or your local fabric store. Bonded batting comes pressed in rolls and loose batting comes in a bag.
Lay the muslin out and cut two pieces: one for the vinyl and t-shirt layer and one to cover the foam panel. Cut them about 6" larger than the plywood so that it will wrap around easily.
Cut the vinyl the same size as the muslin.
To cut the foam, use a razor knife with a new blade in it. Make several passes and be careful to follow along the last cut so that the piece is nice and even all around.
With the foam cut to size, then cut an angle along the bottom edge (figure D). The reason for the angle is so that when you wrap the muslin over the foam, you will have a nice smooth transition with no ridges.
Cut the batting that goes in between the muslin and the foam.