bed part four.

Joinery (sort of continued) ...

OK, so over the last couple of weeks I have been struggling with how to join the siderails to the posts for this design (and even the headboard and footboard although I partially solved the problem with using the biscuits I routed). The requirement still: no screws can show anywhere on the bed.

So I had gotten some brackets from Rockler Woodworking up here along with a burly hangar bolt and wood screws. Then I thought I'd make my own from 2x4's and use tee-nuts and such. Still, nothing seemed to quite work. And to give an idea of how many options I tried - when I went to return the various brackets and hardware I didn't use it added up to about $50.

But then I hit gold with the idea of using pocket hole screws. I had to go out and get a $20 Kreg jig but I was hoping it would work. It has to be super-duper burly and strong since all the weight of the rails and 2x4 horizontal mattress supports, mattress and, well, my son will rest on these joints. I didn't want it to fall apart one night while he was fast asleep ...

So I tested this out last night with my little mock setup of the headboard/post/siderail I had made to test all my different ideas before doing the real deal -

And wow with only two screws (2-1/2") this joint was strong! I assume it's because you only drill partway in - then the screws that Kreg makes are self-tapping which really embeds them tight in the wood. I'm going to beef it up though and put in three screws for each end on the actual rails just to be safe.

This setup meant I had to cut off a smidge more from each end of the siderails where I had notched them in order for the screws to work (which meant holding each 6' rail upright and slide it along my table saw - good times - then chip the remaining wood away with a chisel like I had originally done when I routed them) but I have both rails done and now I just need to drill the holes for the inside of the headboard and footboard (just the lowest section that attaches - the top section I'll let go with just being glued using the biscuit joint.

Strong. And no screws showing. Perfect.

This is a lot of fun building I must say!