Chelsea Top Bunk

Mark the headers as shown above and carefully cut out with a jigsaw. Sand cut edges.

I know it's not easy to cut 1 1/2" thick stock with a jigsaw - practice, take your time, give yourself room to make errors. You will need to cut two of these. Once you have both headers cut, clamp together, and sand the top edges until both match perfect. Start with coarse sandpaper and work your way down to medium grit.

Step 2

On the panel, if you are using the Kreg Jig, you will want to drill all pocket holes before assembly. If you do not have a pocket hole jig, what you can do is use the 2x2 legs to screw the header in place, and attach the header to the panel with glue and clamps. You will need to attach the headers to both panels as shown above.

Step 3

Now attach the base trim to the panels on the outsides as shown above. Use 1 1/4" finish nails and glue.

Step 4

This is what I was referring to in step 2 - if you do not have a pocket hole jig, you can screw through the legs into the header with 3" screws (predrilled with a countersink bit) and this will keep the header in place. You will need to apply ample glue along the bottom edge of the header if you take this route. Attach the legs to the panel. Use either countersunk screws from the outsides of legs, or pocket holes drilled in step 2.

Step 5

Step 6

Guardrails. Guardrails are super easy, the tricky part is building them square. Start by attaching the guardrail boards to the guardrail legs with 1 1/4" finish nails and glue or screws. Adjust for square. Then fill in any gaps with scrap 1x3s.

Step 7

Cleats. Attach cleats flush to the bottom with 2" screws and glue. Place screws every 6-10" apart.

Step 8

If you are not using a bunkie board, lay slats on cleats and screw down.

Step 9

From the underside of the bunk, screw the bunk to the bookshelf or desk as shown above.

Finishing

Sand all surfaces, starting with a medium grit and finishing with fine. Wipe off the dust, fill any holes or gaps with wood filler, and sand smooth once dry. Apply primer if you're painting, then finish with your choice of paint or stain and seal with a durable clear topcoat. For outdoor projects, use exterior-rated primer, paint or stain, and sealer so the piece stands up to the weather.