Make Your Own Rustic-Chic Headboard From Salvaged Doors

I hate watching home remodels that result in destroyed architectural components that could have been either reused or donated. Old doors are a good example. Here's how to turn a pair of weather-beaten cast-offs into a handsome headboard.

If you're not remodeling, then good places for finding old doors (besides the curbs where folks put out trash) include consignment and salvage shops.

The doors shown here originally measured 34 inches wide and 80 inches high and had no hardware installed. The finished headboard is 68 inches wide, 66 inches high and 2¼ inches deep; it fits up to a queen-size bed.

Materials:
(3) 12-inch mending plates(1) box of #12 by 1¼-inch wood screws(3) 6-inch black gate hinges(2) black gate handles (optional)Tools:
Circular sawDrillA few clampsYou can lean the assembled headboard against the wall (with the bottom resting on the floor), or you can attach it to the wall using two interlocking boards called a French cleat.

To make a French cleat, you'll need:
Table sawLevel1-by-6-by-6 boardA few 1⅝-inch wood screwsSome 3½-inch wood screwsTo prep the doors:
Measure 66 inches from the top of each door and mark a line across the entire width of the door. Check for and remove any hardware in the path of this line. To help minimize tear-outs and jagged edges when cutting, apply masking or blue painter's tape to the cut line. Mark the line again on the tape. Cut the doors at this length using a circular saw with a straightedge guide.
Attach the Mending Plates

Position the top (uncut) ends of the doors so they line up perfectly and clamp the doors together. Position a 12-inch mending plate no more than 2 inches from the bottom (cut) end and centered across where the two doors meet.


Drive the #12 by 1¼-inch wood screws through the two inner screw holes of the mending plate first, then drive screws through the remaining holes.


Attach the remaining mending plates at the top and center of the doors.


Attach the Decorative Hinges and Handles

Flip the assembly over. Clamp the doors in place and position a 6-inch black gate hinge near one end, making sure to position the screw holes so they are not in line with the screws of the mending plates. Mark the position of the hinge and screw holes. Drill pilot holes for the screws.

Mark the positions of two more gate hinges and their screw holes, one near the other end and one roughly centered. Drill pilot holes for the screws.


Attach the gate hinges using the included screws.

If the doors you selected have knobs or handles already installed and you want to keep them, you can skip the next step.


Position the gate handles where desired on the outside stiles of both doors. For this project the handles are 31 inches from the top end. Mark the position of the screw holes, drill pilot holes and attach as recommended by the manufacturer, in this case using a socket wrench.



If You're Attaching the Headboard to the Wall

A French cleat is essentially two interlocking boards that have been cut along their length at 45 degrees. Many cabinets are attached to walls via this method, as it is very sturdy and can support a lot of weight.

Start by marking a centerline across the end of the 1-by-6 board. Mark the center point of this line and draw a 45-degree angle that bisects this center point.

Set the saw blade on your table saw at 45 degrees, then set the fence on your table saw so that the 45-degree mark lines up with the saw blade. Rip the 1-by-6 into two long pieces, creating two interlocking boards — one for the headboard cleat, the other for the wall. Cut them to 60 inches in length.



Position the headboard cleat flush either with the top mending plate or with the top rail of the doors, and attach it using 1⅝-inch screws. Make sure the long point of the cut side is positioned away from the salvaged door.

Enlist someone to help you take the assembly to the desired location. (If you're working solo, you can take it apart and move it one door at a time. Reassembly goes quickly once you've done all the cuts and drill holes.)

Install the Headboard

Position the headboard assembly in the desired location and flush against the wall to which you plan to attach it. Place the wall cleat flush underneath and against the headboard cleat. The cleats should fit snugly against each other. Mark the position of the wall cleat.

Remove the assembly and use a level to square the wall cleat. Attach the cleat to the studs in the wall (make sure the long point of the cleat is away from the wall) using 3½-inch screws.

Hang the headboard on the cleat. Then stand back and enjoy the look of your new headboard!

More: How to Find a Stud With a Magnet

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