I built this Old World Headboard by re-purposing a door.
I started out with a 6 panel door and a couple of 4×4 fir posts.
Cut post to length and chamfered the tops.
To attach the door to the posts I needed to cut a large mortise on each post. I started out drilling 1-1/8” wide 2” deep holes, 72 of them.
To square the top of the holes and cut to the width of the door, I used my router equipped with a pattern cutting bit against my straight edge.
Out of all my router bits I did not have one that would cut deep enough so I hand chiseled out the bottoms and square cut the corners.
A standard door is too long to be used as a headboard so I had to cut the bottom off. Sadly it was a hollow core door and once I cut the bottom off it was no longer stable, so I glued in some support blocks.
Support blocks glued in and I’m ready for assembly.
All assembled and ready for paint; Final painting will be done by my customer.
If you would like a custom made headboard built for you, just follow this link.