As a side note, I cannot say how much I love tech shop. If you are unfamiliar with it, it is a workshop with the tools and machinery to allow you to build pretty much anything. They have several locations throughout the country, but I am fortunate enough to belong to the one in Detroit. Using TechShop, I was able to take a $40 sheet of plywood and turn it into a headboard to my exact specifications. Their staff is super helpful and guided me through the entire process. If you have the chance, I highly recommend you at least go in for a tour...its free and you wont regret it. (Im not paid or compensated in any way by TechShop to say this, I just know that I would want to know about a place this cool)
I then cut the board out with a 1/8" end mill bit.