Bunk Bed

Last year, I built my son an under-bed drawer unit, which he thought was awesome:
http://www.johnnyego.com/wood/2017Pr...d/vinbed99.JPG

Until he saw his cousins new bunk beds. Then life was incredibly unfair. My wife just wanted to go to Ikea and pick up a cheap pressed wood bunk bed like the cousins had, but at the suggestion of a trip to Ikea, I experienced a mild brain aneurysm that impaired my ability to comprehend the time-value of money. So I went to Lowes and came home with this:

http://www.johnnyego.com/wood/2018Pr.../bunkbed02.JPG

Because I didn't want to ruin $160 worth of blade and brake cartridge on $80 worth of lumber, I switched to a cheap ripping blade and pulled out a crap-load of staples.
http://www.johnnyego.com/wood/2018Pr.../bunkbed01.JPG
http://www.johnnyego.com/wood/2018Pr.../bunkbed03.JPG

Then I ripped a crap load of 2x4s:
http://www.johnnyego.com/wood/2018Pr.../bunkbed04.JPG

Then I started notching them with a dado blade:
http://www.johnnyego.com/wood/2018Pr.../bunkbed13.JPG
http://www.johnnyego.com/wood/2018Pr.../bunkbed12.JPG

Next came a lot of glue and pocket screws:
http://www.johnnyego.com/wood/2018Pr.../bunkbed16.JPG
http://www.johnnyego.com/wood/2018Pr.../bunkbed15.JPG

A lot of pulling mortices together later, and I end up with something that looks like a bunk bed:
http://www.johnnyego.com/wood/2018Pr.../bunkbed19.JPG

Normally, I like to fill and paint at this point. However, I needed to get all these parts through the bedroom door, so I had to keep it as a knock-down set-up, which precluded my ability to glue the rail supports if I ever wanted to take it out of my son's bedroom without an axe. So I pulled the whole thing back apart. I repurposed a target stand, some dollies, and some scrap to build a parts rack.
http://www.johnnyego.com/wood/2018Pr.../bunkbed21.JPG

Prime twice, then sand. 2x4s are cheap, but they are also soft and kind of crappy for furniture purposes. I ended up sanding pretty aggressively (80 grit, 120), followed by two coats of primer and a lot of filler, followed again by an aggresive sanding at 180 grit. I could have saved a lot of time instead of money had I chosen a better grade of material. However, this is a 4-8 year bunk bed for an 8 year old, and not a Shaker cabinet, so pine it was.
http://www.johnnyego.com/wood/2018Pr.../bunkbed22.JPG

Yay! Two coats of Rustoleum enamel in gloss black.
http://www.johnnyego.com/wood/2018Pr.../bunkbed24.JPG

Final assembly was... rough. I put the wrong side of the rail on, and didn't realize until half way through, when I had to pull it back apart. Also, some touch-up paint is going to be necessary at the rails. But it's in there. The general guidance was 24" of clearance from the sleeping surface for the top bunk. There is 32 inches to the floor of the bunk, but that still doesn't leave a lot of clearance over the top rail:
http://www.johnnyego.com/wood/2018Pr.../bunkbed25.JPG

I told my son I wanted to take 6" off the legs, but he is demanding that I keep it high. That may change by the time he turns 10, but I will worry about that in another two years.
http://www.johnnyego.com/wood/2018Pr.../bunkbed28.JPG

Mattress gets here on Wednesday, but son has already moved in.
As a final note, I probably should have just given my wife $250 and sent her into Ikea.
But my son seems happy, so I am happy.
http://www.johnnyego.com/wood/2018Pr.../bunkbed30.JPG

Nice job keeping the original bed. I bet your bed is more sturdy, and less creaky, than the metal one we got for our kid.

It holds my fat ass.

The cross supports are 2x2s on 16" centers, with a 1/2" Melamine deck. Better build then a lot of roofs I've been on. The cross-bracing probably wasn't necessary, but I can lean on a corner with my full body weight, and the thing doesn't creak, wrack, or move.

I've often thought that our bed would have creaked a lot less with cross supports. I haven't quite ruled out the idea of some turnbuckles off of a wooden gate to tighten things up. Another project well done.

Next project: ten foot ceilings in the kids bedroom.

Looks great!

Good job, dad.

Nice job!

Very nice job!!!


Screw Ikea!