I'm planning to build a canopy bed with strong posts, ideally 3x3 or 4x4 inches, to support some weight. I initially thought about using solid ash or maple 4x4s, but that's quite pricey. So I'm considering making the posts from thinner materials and laminating them. My current idea is to use two 2x4s, glue them together, and then apply veneer to get a nice finish. However, I'm also exploring the option of using birch plywood, cutting a 4'x8' sheet into 3" strips, and gluing four together to create 3x3 inch posts. Using plywood seems like a cost-effective way to make all the posts and skirts for the bed while applying veneer for an attractive finish. What do you all think?
4 Answers
Are you expecting a static load, or will it be dynamic, like a swing?
I've made something similar using 2x4s before. Just make sure to pick high-quality ones, and sand the gluing surfaces really well. After cutting them down to 3 inches on a table saw, I stained them and the results were solid. I also tried 1x4s, which were easier to clamp during assembly, but they did cost a bit more.
If you're using plywood, I recommend getting a mitre lock bit and jig for your router. It will make joining the plywood a breeze and add some strength. For the plywood, using structural grade CD ply is a good idea—it won’t have voids inside and offers a reliable gluing surface. Just be careful to avoid non-structural stuff when you pick it up.
Using plywood could definitely work. I think gluing those 3" strips together would provide sufficient strength and minimize twisting or warping.
Yes, I'll be hanging a swing! I'm planning to connect the top rails to the posts similarly to my pergola, using load-bearing brackets, which should distribute the weight evenly since the swing will have two contact points.