We purchased a bedroom set back in November. When it was delivered in January, we discovered that we no longer needed the box springs for our bed. We took the box springs and set them outside on our deck. There was no interest when I posted them for sale or even for free. When I realized that we were going to have to throw them out, I began to think what I could do with them. I settled on the idea of a small transport sled when we received layers of ice and snow.
Step 1: Tools Needed and Materials Needed
These are the different tools that I used over the entire course from stripping the box springs to attaching the rope.
Drill with various sized drill bits and screwdriver bits
Needle nose pliers
Sander with different grit sandpaper
Electric staple gun and extension cord
1 box spring
assortment of wood screws
2 metal D rings with plate
Length of rope for pulling
Step 2: Stripping the Box Springs
I unfortunately do not have pictures of this step. I used a sharp box knife and large scissors to cut the fabric off. I used bolt cutters to cut the metal springs off the wooden frame. Set the metal frame to the side and throw away the metal springs. The staples were pried off of the wooden frame using a screw driver, hammer, and a pair of pliers.
Step 3: Wooden Frame
This is what the frame of a box spring looks like. I hammered it apart and then nailed the nailed out the other side and pried them out.
Step 4: Raw Wood and Choosing What to Use
I am left with what looks like a pile of scrap wood. Out of one box spring I was able to get 2- 6.5', 2- 39" (with a piece of 1x1 nailed on the bottom edge that I left attached), and 6-37" lengths of 1x4. I chose the 2 lengths that had the extra wood nailed on for my runners and used my 37" lengths for my runners. I cut up one of my longer boards for supports.
Step 5: Measure and Cut
I measured and cut the support pieces. I chose 12" for each support.
Step 6: Cut Off Runner Ends
I trimmed the rounded end off the runners on one end.
Step 7: Trim Supports- Top Edge
I trimmed about 1/8" off the width so that my longer boards would sit flush with the top of my runners.
Step 8: Decide Placement of Supports
I planned where I wanted to place my supports for my sled. I measured and marked.
Step 9: Predrill Holes
I have a tendency to crack wood when I screw it into place so I usually predrill my holes. I think it also make assembly a bit easier. I also took the time to drill the beginning with a larger drill bit size so that I could countersink my screws. I do not want them poking kids while riding or digging through my metal runners when on snow.
Step 10: Screwing Into Place
I screwed each support into place on one side through the bottom of the runner.I used a square to get them as square as possible. Repeat on the other side. I now looks like a mini wooden ladder.
Step 11: Side Screws for Supports
Screw in all the sides. I used 2 screws for each support on each side.
Step 12: Time to Rough Sand
At this point it should look like a sled with the top off. I took it outside to get a few of the supports more even so the longer boards would sit even. I also took the sander to all the other sides and did a rough sanding.
Step 13: Starting on the Top
Now I selected which boards I wanted to use for my seating area. All of the boards have some marring from the staples and from the metal springs but it is after all a recycled product. I selected and pre drilled my holes. Again I countersank my holes so the screws wouldn't poke.
Step 14: Determine Where Remaining Slats Go
Now I had to determine where I wanted the remaining 2 slats to go on top. I screwed and countersank the screws in.
Step 15: Runners
This is my almost completed sled. I wanted my sled to glide super easy so I chose metal flashing to cover my runners. I cut the metal a bit longer then the length so I could wrap it up the front edges. I then cut the metal flashing in half and rolled up one side and the front of the edge where it would possibly be exposed to fingers.
Step 16: Attaching the Metal
I used a power staple gun to attach the metal to the runners. I placed the unrolled edge inside and the rolled edge to the outside. Slowly bend the metal around the bottom of the runner and screw into place. It's handy to have someone help hold while you screw or use a clamp.
Step 17: Curving the Front
Step 18: Attach Hardware and Rope for Pulling
The most time consuming part of building the sled was salvaging the wood from the box spring.