Measure and Cut Plywood
First, determine the headboards desired width and height. To determine the board’s width, multiply your mattress’ width by four inches. Ours is four tall; you might want to make a headboard that is shorter or taller depending on the available space. Since plywood is sold in 8′ by 4′ sheets, have the board cut to the size you want when you’re at the store.
To ensure that the pool noodles lay flat against the plywood, cut each one in half lengthwise using an electric knife. Place the chopped noodles on the board momentarily to evaluate any gaps. Then, cut any smaller pieces that are required to fill in any gaps using the electric knife.
To make the blanket easier to work with during the upholstering process, trim it to leave 8″ of extra fabric on either side of the headboard. Maintain the length as is; additional fabric will be needed to create the illusion of channel tufting upholstery.
After applying construction adhesive to the first row of noodles’ flat side, line them up with the plywood’s upper edge, and hold them there for a short while. Use duct tape to hold the noodles in place if you’re worried they’ll move around while the adhesive dries.
After that, staple the blanket’s upper edge to the plywood’s back. Make sure the fabric is correctly oriented if you’re using one-sided or directional so the “good side” hangs as intended when flipped over to the front of the headboard.
After it’s secure, turn the blanket back to face the top row of noodles and wrap it snugly around it. Secure the blanket with staples all the way across the headboard, right under the noodle.
Using adhesive, apply the next row of noodles, flip the blanket to the back and out of the way, flip it back to the front to cover the new row of noodles, and then staple the blanket in place to finish the upholstery process. Continue the process until you reach the plywoods bottom edge.
Tightly wrap the remaining fabric around the plywood’s back along the headboard’s sides and bottom, and fasten with staples.
To reduce bulk, trim any extra fabric from the headboard’s backside, then tape down any exposed edges.
To prepare the headboard for installation, remove the paper backing from the “wall side” strips and apply multiple sections of removable adhesive to the back of the plywood.
Place the headboard carefully and firmly against the wall with the assistance of a friend. Hold for a bit, while the adhesive strips set.
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Step 2: Back It Up
Roughly cut the foam board backing to the same size as the combined channels. Pro tip: To make it blend in with the arched edges, you might want to make it a little smaller. You can also attach fabric to this section to create a really seamless appearance.
