DIY channel tufted headboard

First, I drew the pattern on the wall with chalk to see if the pattern I had in mind was suitable and to determine the dimensions.

Then I transferred the pattern to plywood and cut it out. After cutting out the shape I used 1×2 pine to frame out the back of the plywood and create some depth to the frame, and also create 4″ feet to bring my headboard to the proper height.

My headboard spans the whole 14′ width of my bedroom. So I had to make the headboard in three sections in order to be able to move it and handle it.

I created the curved corners with plastic flexible trim moulding from Home Depot.

I measured the middle section of the headboard and evenly divided it into 8″ sections. I stapled cardboard tack strip on top of the pencil drawn line from bottom to top. The tack strip has two purposes. It provides a straight line to follow and it provides a tactile guide that can be felt through the layers of fabric.

The picture above is Dacron. It’s upholstery batting, which is very hight loft, dense batting. It’s not the same as quilters batting. You can buy a whole roll of upholstery Dacron at the fabric store by the yard, or go to your local upholstery supplier and buy it by the roll for much cheaper. I cut all my Dacron strips ahead of time. I like to do my projects assembly line style to try to be as efficient as possibly. I’m not a fan of task switching.I also cut all my fabric strips right away. I cut my fabric strips 12″ wide, so I’d have plenty of fabric to pull and staple, and allow for the crown(poofy-ness) of the Dacron. Nothing’s worse than stapling into a fraction of an inch of fabric while trying to pull it taught.

Start the very first strip of fabric on outside edge of the frame. Take care to make the first piece straight and staple the fabric all the way down the frame. Place the Dacron between the tack strip and fold the velvet fabric over the Dacron and staple the fabric tight over the Dacron, stapling the fabric to the tack strip. Feel for the tack strip as you move your staple gun to make sure you’re stapling into the tack strip. This will keep your seams straight.

After the first strip of fabric is stapled down, cut off the excess fabric so it lines up and reveals the tack strip underneath.

The next strip of fabric is then placed right side down on top of the first strip of fabric. Make sure the edge of the top piece of fabric is lined up perfectly to the first tack strip and staple it down.

Then staple another piece of cardboard tack strip right on top of the first tack strip and fabric. This cardboard will create a very straight and sharp seam between the channels.

Make sure you have 3/8″ staples, otherwise the staples will be too short to reach the wood and will pull out of the cardboard.

Lay down two more pieces of Dacron. I used two layers of Dacron so my headboard would have a bit more fullness.  You can use only one piece if you prefer a flatter looking headboard.  Usually upholsters will use 1″ foam with a single layer of Dacron over the foam. But, foam is very pricey and I prefer to not use the petroleum laden stuff anyway.

Then repeat the same process over and over until you reach the end.  Fold the fabric over the Dacron, smooth it out, make sure it’s taught and staple it down.

The last step is to finish off the top of the headboard.  I boxed mine out with welt in front and back. I couldn’t get the fabric lay down smoothly over the curve on each side, so I opted to use welt in front and back.  If you plan to make a rectangular shape headboard with no curves you can simple wrap your fabric over  the top of the headboard and staple it to the back of the frame and be done. No messing with welt. But I had to complicate things and make curved corners.

The welt gets stapled on first. Then the fabric, then a strip of cardboard tack. Fold over the fabric, insert a strip of Dacron and staple the fabric to the back of the headboard frame.

The last step is to attach one more piece of welt along the back of the headboard frame and install.I made my headboard in three pieces for ease of installation. The hallway leading to my bedroom is narrow and long so a 14′ headboard wouldn’t fit. Not to mention I don’t think I could’ve managed upholstering it in one piece. So I had to screw together the three pieces in my room. Fortunately one screw was sufficient to pull the pieces together at the seams, and the seams are almost imperceptible.

Supplies List:

cardboard tack strip… https://amzn.to/3f6f5Mb

staple gun… https://amzn.to/3f5vQaq

compressor… https://amzn.to/2KQQZac

fabric…  your choice of upholstery fabric

1×4 pine…  Home Depot

flexible moulding… Home Depot

upholstery Dacron… https://amzn.to/3d53QBI

underlayment plywood… Home Depot.            1/5 in. x 4 ft. x 8 ft. Hardwood Plywood Underlayment Specialty Panel  

screws… Home Depot