Step #1. First things first, you must be able to transport your lumber to your work space. Because I measured the headboard to be 48in by 60in for a queen sized bed, I purchased my particle board at Lowes. They will only cut straight cuts, first two for free and every other is an additional 50 cent.
Step #2. Once you get all your materials to your work space, start by laying out your tarp in a ventilated indoor or oudoor space and take your foam bed toppers and begin spraying adhesive on the inside pieces and attach them to each other (remember not to spray the outlaying sides of the bed topper foam) . Allow 20-30 mins for the adhesive to dry and the foam bed toppers to become one solid piece.
Step #3. While your foam toppers are being fused together, you should now brace the lumber together to make it a solid piece ( this is if you were unable to transport it in one solid piece, if not continue straight to step 5). Take your multiple particle boards and aline them side by side.
Step #4. Put your flat medal braces on the top corner and middle areas where the particle boards meets. Have your screws and power screw driver on hand and begin to screw the flat medal braces onto the particle boards. Do know that after your done screwing the flat braces to the particle boards, the side without the braces will be the side you will be mounting onto the wall.
Step #5. Get your drill and measuring tape ready. You will need to determine where you want to drill your tufting holes. After you drill each hole be sure to take your maker and mark on the wall mounting side of the particle board so that it is easy to locate later.
Step #6. Take your foam bed topper and lay it on top of the particle board and take the scissors and cut it to the shape of the particle board. After your done, take your fresh cut foam to a ventilated indoor or outdoor space and spray the glue adhesive to the side that will lay on the particle board. After spraying immediately lay the foam topper onto the particle board and allow 20-30 mins to dry.
Step #7. Take your cotton batting and lay it flat onto the top of the foam that has been glued to the particle board. Get your staple gun ready and begin stapling the cotton batting tightly to fit the front of your soon to be upholstered headboard.
Step #8. Once your batting has been stapled to the particle board take out your preferred fabric and lay it onto the board to make for sure it measures to your desire onto the foam fused particle board. Note that before you attach the fabric you will need to iron it so that you can get rid of all of the random creases. When your done lay the fabric flat onto the ground with the outside view of the fabric facing the floor. take your staple gun once more and begin stapling the fabric to the particle board making sure your keeping a tight grip as your staple.
Step #9. You've stapled the fabric to the particle board. Now lift it off the floor and anchor it on something ( the wall or anything stead enough to hold it while you begin the tufting process). Get your upholstering needle, thread, tufting buttons, flat washers, and additional fabric together. Take your tufting button kit and follow the directions on how to add the fabric to the buttons. You should be able to find it on the back of the box it comes in. When your done adding the fabric to the buttons get your needle and add the upholstery tread to the needles threading hole. Take the end of the thread and tie it onto the flat washer into knots. To tuft a headboard with the holes drilled for each button, bring the needle back through each hole, thread the needle through each tufted button and pull tight. While your pulling, wrap the upholstery thread around the back of the button as many times necessary to secure it. Once it is on tight, cut the thread from the needle and tuck the access behind the button so it doesn't show.
Step #10. You've done tufting your buttons to your headboard. Now we need to mount it to the wall above the bed. Get your power screwdriver, screws, flush mounts, Measuring tape, marker, and a large flat sheet of paper to use as a template to measure your flush mounts with. Take your stud finder and locate where the studs are behind the wall, mark them with your maker. When your done, take the measuring tape and measure where to screw your flush mounts to the wall being sure they will be screwed directly into a wall studs. Get your power screwdriver and screw in the flush mounts on the desired areas of the wall. Get your construction paper ( depending on the size,. you may have to tape them into a larger square size) and post it onto the wall where the flush mounts screwed in and mark onto the construction paper where the flush mounts are screwed onto the wall. Afterwards, take the marked construction paper and lay it on the back side of your headboard at the exact area that you plan to hang it. Take your opposing flush mounts and screw them onto the markings on the construction paper that will enter into the particle board. Your almost done! You can take your new custom headboard and mount it onto the wall now.
Your beautiful custom headboard is done and ready to be enjoyed!