Measure the book board with a ruler to get the size you want for your book cover. Mark the dimensions with a pencil. Divide the book board into two halves that will give you a front and a back cover. Use a utility knife to cut out the covers.
Create signatures to go inside your book. Each signature consists of several pages that are folded in half. Signature pages can be folded in portrait or landscape orientation, depending on your needs. Determine the number of pages you want in your signature, and fold each page in half. Put the folded pages together by placing them on top of each other in the same manner as that of a saddle-stitched periodical so that the folded pages interlock and are held together as a unit.
Place signatures and book board together for hole-punching. Use paper clamps to hold the signatures and book board in place. Measure and mark around four or five equally spaced points for holes. Use a Japanese Book Drill to punch holes in the signatures and the book board.
Sew the book board and signatures together using waxed linen thread. Work with one signature at a time and sew it to the book board completely. Start by sewing from inside the first signature’s fold.
Run the thread through and out the first hole. Bring the needle down to the outside of the book board cover and run it through. Take the needle back through the first hole of the signature and tie a knot to hold it all together.
Move to the next hole and continue sewing the signature to the book board. Do this for both the back and front cover of the book board. Run thread through all holes and tie another knot after stitching the last hole to finish.