Here are some detailed instructions on how to fabricate the pieces
that will make up your OP Bunkbed. Since only minimal woodworking
skills and tools are required, almost anyone can build the entire
bed in about 12 hours.
| Tools Required:
Circular saw, drill, drill bits, tape measure, pencil, combination
square, screw driver, 9/16" wrench, adjustable wrench,
chisel, wood glue, and clamps.
Do not forget safety equipment: Safety
glasses, gloves, and ear plugs.
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| Optional tools:
These will simplify construction: drill press, miter saw, table
saw (not shown). |
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| Step 1 - Measure
and cut all pieces. Most of the individual measurements are
on pages 4 and 5 of the purchased plans.
Measure and mark pieces for saw cuts (always double check
all measurements against plans). Remember: "Measure twice,
cut once!" |
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| Make sure all cuts are right angles (use combination
square). |
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| Cutting with a miter saw will
insure all cuts are at right angles. |
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| If you do not have access to a miter saw, a circular
saw will do the job. A hand saw will work, but it may take forever.
|
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| Step 2 - Measure
and mark locations for drilling holes. Most of the individual
measurements are on pages 4 and 5 of the purchased plans.
Always double check all measurement against plans.
|
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| Using a drill press will insure
that all holes are at right angles. |
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| If you do not have access to
a drill press, a hand drill will work. Try to make the holes
as close to right angles as possible. (This will make assembly
easier.) |
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| Step 3 - Make the miter cuts on the
ends of the mattress support pieces. Set the circular
saw (or table saw) blade to 45 degrees. |
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Step 4 - Cut the inside
notch on the mattress support pieces. The photos here
illustrate how the plywood will rest in this notch.
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Circular Saw Method of Cutting Notch
Set the circular saw blade depth of cut to 3/4" for
cutting out the 3/4" x 3/4" notch.
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If available also set a rip guide to a distance of 3/4"
from the blade.
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Rip the mattress support on the wide side of the board.
Note: This photo shows a short piece of 2x6 being used.
It is a good idea to test your saw set up on a scrap piece
of lumber before making the cuts on your final mattress
support piece.
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Rip the mattress support on the narrow side of the board.
(Be sure that the board is held securely for this step.)
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Remove the wood from the 3/4" notch. Save this picece
of wood to use on top of the the OP
Loftbed Guardrail Side Table.
|
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Table Saw Method of Cutting Notch
Set the table saw blade depth of cut to 3/4" for cutting
out the 3/4" x 3/4" notch.
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Set the rip fence to a distance of 3/4" from the blade.
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Rip the mattress support on the wide side of the board.
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Rip the mattress support on the narrow side of the board.
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Step 5 - Assemble the Legs
Use a 1/8" drill bit to predrill the pilot holes in
the 2x4 leg piece. Use the 1/8" diameter holes in the
2x6 leg pieces as a guide. |
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| Remove the 2x6 board that you used as a guide
and finish drilling the pilot holes in the 2x4 piece. |
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| Apply a bead of wood glue on the leg pieces before
assembling. |
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| Assemble the leg pieces with #10 x 3 1/2"
long wood screws. |
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| The left and right legs should look like
mirror images of each other when properly assembled. |
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| Step 6 - Cutout
the lap joint in the X-braces
Temporarily assemble the bed to locate the lap joints on
the x-braces.
|
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| Make marks on both sides of
the x-braces where they cross each other. |
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| Then set the circular saw blade
depth of cut to 3/4" and make several cuts between the
marks on the x-braces. You should be able to break out these
pieces with your finger. |
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| The lap joint cutout can then
be smoothed out with a chisel. |
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| Step 7 - Assemble the center mattress
support.
To make the center mattress supports, glue the center pieces
together and draw them together with #8 x 2" flat head
phillips wood screws.
|
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| To complete the center mattress supports, attach
the end pieces with 4 #10 x 3-1/2" flat head phillips wood
screws. |
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| Step 8 - Assemble the shelf.
To make the shelf, attach each of the two side pieces with
#10 x 3-1/2" flat head phillips wood screws. |
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| Attach the top and bottom of the shelves with
#8 x 2" flat head phillips wood screws. |
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| Depending on your personal preference, the shelves
can have any shape that you choose. (Angled and Square Cut shown.)
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If you have further questions about fabricating the pieces of your
OP Loftbed, email them to support@oploftbed.com,
or use our convenient email form.
