As part of my goals for 2019, I am going to try to write about some of my DIY and maker projects. So, here’s an unexpected one to start off the year…
The other evening, I heard a thud and an “uh-oh” from my 11yo daughter’s room. Turns out, when hopping on to the bed to read that night, the bed rail snapped. The bed rail was made from pressboard, veneered to look like the rest of the furniture (which I think is of slightly higher quality). Our daughter felt terrible about breaking the bed, but in reality it’s a wonder it lasted for the 7 years it did. An average size toddler could break this stuff, let alone an average size 11 yo girl. The pressboard had cracked in two pieces, right through one of the screw holes for holding the slats.
We considered purchasing a new IKEA bed or similar, but she said she really like this bed and would prefer if we could just fix it. Maybe that was partly her still feeling bad for having done it, despite my wife and I assuring her it wasn’t really her fault at all. The only downside to this was that I was going to have to purchase a full size sheet of plywood at the big box store to get the 6′-6″ rails out of them. I normally have the store cut the board along the short dimension, so that it’s less than 7′ long as to fit into my Honda Pilot. However, in hindsight, I should have had them then rip down some strips to make it easier to manage. A 6′-8″ by 4′ sheet of 3/4″ plywood is only slightly easier to manage by yourself than a full size sheet.
I did get to try my hand at edge banding the plywood. Edge banding is a narrow, thin strip of veneer (almost exactly like the surfaces of hardwood plywood) that has a heat-activated glue on the backside. You simply iron-on this to the edge of your cut plywood.1 It’s actually a lot of nice furniture and cabinetry is made and it’s a pretty amazing transformation. Of course, it’s also how a lot of cheap furniture is made, too, but that’s often a plastic veneer rather than actual hardwood. I couldn’t find maple veneer at my big box store, so I took a trip to my local Woodcraft shop. There, I also got a self-centering drill bit. I’d always considered one of those to be for someone who makes a lot of furniture or cabinetry, but it’s worth it to buy some even for DIY’ers like me. It’s a huge timesaver for mounting hardware and really makes the process more accurate.
So, I ripped down the nearly full sheet of plywood on my little band saw. Again, I should have had the store cut this down, because it’s just not easy for one person to do this on even a high-end cabinetry saw, let alone a my small Ryobi2. It resulted in some not-so-straight cuts, but they were good enough for this as I wasn’t jointing anything. I straightened out some of the bend metal slat supports in my machine vice and then got all the screw holes drilled out.
I did a small test piece with the edge banding and tried using one of those spring loaded edge banding trimmers. The banding went on easy, but the trimmer was not so great. It ended up tearing the banding in a lot of places. I still tried using it one the first rail, which was a mistake. When trying to sand everything, the orbital sander grabbed one of those tears and ripped off a huge chunk of the banding. Fortunately, I was able to cut out that piece by re-heating the glue and Angela helped me put on a patch. It ended up looking just fine for our kid’s bed, but I learned my lesson. For the second rail, I simply flipped the piece over and cut along the edge with a box-cutter blade. I then lightly sanded over the corner with a sanding block.
I used a single (though pretty heavy) coat of wipe-on polyurethane for the finish. The final step was to stamp the work and then it was ready for assembly this afternoon. The final clip sliding in to place was so satisfying! The maple matches the furniture, but of course it will have to darken over time with exposure to light to fully match. But, I’m pleased with the final result and I’m confident this will last longer than the original.
- If you want to know more about edge banding, Bob of ILTMS made an excellent “Bits” video on the subject late last year. [↩]
- It’s actually my older brother’s table saw. He just needed a place to keep it and I needed one to use, so that worked out for us. [↩]