How to Make a Bunkie Board for a Bunk Bed

The height of a bunk bed, along with the shallowness of the side rails, make using standard box springs impractical and dangerous. The remedy for this situation is called a bunkie board. A bunkie replaces the box spring and provides support to the mattress. Bunkie boards can be quite expensive. However, you can build one for far less than the retail price. Strength and safety are the first consideration when constructing a bunkie board. A thin plywood assembly topped with foam will supply the strength you need and the padding you want in case the mattress becomes dislodged.

Tape measure
Pencil
Chalk box
3 sheets of 5/8 inch plywood
Circular saw
Jigsaw
Construction adhesive
Bricks
Roll of 3 inch foam
Cloth
Staple gun
Shears
Work gloves
Safety glasses
Hearing protection

Instructions

- 1
  Measure the inside dimensions of the bedding area of the bunk bed. Transfer those measurements to each of your three sheets of plywood.
- 2
  Stretch your chalk box across each sheet of plywood between your pencil marks. Pop the string against the plywood to leave chalk marks outlining the size of the bunk bed.
- 3
  Cut along each of the lines with your circular saw. Cut each piece of plywood to the desired size. Stand each piece of plywood on its end and tap it on the ground to get rid of any sawdust.
- 4
  Lay a piece of plywood onto a flat surface. Apply a grid of construction adhesive onto the wood. Space the beads of adhesive 4 inches apart each way.
- 5
  Lay a second piece of plywood on top of the first. Apply adhesive to the second sheet of wood and lay the final sheet on top of the stack.
- 6
  Maneuver the three pieces of plywood to even the edges of the stack. Lay bricks on top of the stack of plywood to weigh it down. Leave the stack overnight to allow the adhesive to cure completely.
- 7
  Remove the bricks from the plywood assembly. Apply construction adhesive on the top of the plywood. Cut a piece of three inch foam with your shears to fit the plywood. Press the foam into the adhesive.
- 8
  Lay a large piece of cloth over the foam on top of the assembly. Flip the assembly and pull the edges of the cloth around the back of the wood.
- 9
  Place a staple every three inches around the edge of the cloth to hold it in place. Trim the cloth with your shears as necessary.

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