Plywood King Single Bunk Beds Using Materials From Bunnings
Introduction: Plywood King Single Bunk Beds Using Materials From Bunnings
Only the 30mm plywood sheets are specific to Bunnings as far as I can tell - the rest of the materials can be purchased at any local hardware store. You could make this project with 25mm plywood available at most timber/hardware stores) however the cutting list will be different and is not discussed in this instructable. I chose the 30mm thick 2250 x 600 sheets because they can be ripped down the middle at any angle you like then joined together to form a very sturdy post.
Supplies
Must have materials:
7 x sheets of 2250 x 600 x 30mm plywood @$62 each - I/N: <PHONE_NUMBER>
2 x boxes of 3/8" x 2 1/2" zinc coated cup head bolts @ $11.30 each - I/N: 2260477
30 x zinc washers 3/8" in size - Zenith Zinc Plated Flat Washer - I/N: 2440400
5 x bolts - Zenith M10 x 60mm Stainless Steel Cup Head Bolt and Nut - I/N: 2310374 (SS cup heads don't have stampings on the cup head therefore look better however you can use zinc cup heads to reduce cost)
4 x bolts - Zenith M10 x 100mm Stainless Steel Cup Head Bolt and Nut - I/N: 2310383
9 x M10 washers - Zenith M10 Stainless Steel Flat Washer - I/N: 2430052
A box of your choice of 50mm screws (I used 10-8 gauge square heads)
A box of 75mm screws if you choose not to do the pocket hole method used in this instructable
White paint (if you choose to paint)
80 grit sandpaper and 240 grit sandpaper
Tools:
Circular saw (I would not recommend cutting with a hand saw)
Drill and impact driver
Router (if you don't have a router, use a wood plane, file, or coarse-grit sandpaper to soften the sharp edges
12mm radius rounding over router bit - I/N: 6371758 (not required if you don't have a router)
2400 long straight edge (cutting long lengths of plywood without one will look bad!
Some sort of square or method of marking angles - Empire 180mm Aluminium Rafter Square - I/N: 5660524
Craftright Pocket Hole Jig @$29.95 - I/N: 6360344 (My jig is a different brand but this will work the same)
10mm HSS drill bit
3mm HSS drill bit
25mm speed/spade bit
Various clamps
Ring spanner/socket/adjustable wrench
2 x saw horses (or milk crates)
Step 1:
Step 2: Making a Post
Sit a sheet of plywood on top of two saw horses or milk crates. This piece of ply will be cut down its length at an angle of your choice. I chose the base of my posts to be 400 wide and the top of the posts (up near the ceiling) to be 200mm wide. On the 600mm end of the sheet, make a mark that is 200mm in from the corner. On the other 600mm end, make a mark 400mm in. 582
When you join the marks together using a pencil and a straight edge, you're left with a long line from one end to the other that is slightly diagonal down the sheet.
Now we want to cut this piece of timber down the line. You can freehand it, or you can clamp your straight edge parallel to the line at a distance that matches the distance your circular saw blade is from the edge of its guide. For me I think the distance was approximately 35mm. Your saw will probably be different. See the photograph; it explains this more clearly.
Cut the plywood sheet in half. These two pieces will be screwed together later to form an L-shaped post.
Repeat for the other three sheets.
Now you should have eight pieces of plywood, 2250 long but 400mm wide one end and 200mm wide the other.
Step 3: Join the Two Pieces to Create an L-shaped Post
I joined my two pieces together using a pocket hole jig and screws because I didn't want to see screw heads due to this project being stained when completed. Half-way through I changed my mind and decided to paint the bed instead, so I could have simply joined the two pieces together with screws that later could be filled over then covered in paint. Ah well, it was a new experience using the jig.
Run some wood glue down the edge you are going to fix to. 415