Project by Jim Jakosh | posted 09-02-2012 08:46 PM | 2041 views | 1 time favorited | 17 comments | ![]() |
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My daughter has this huge 3 story house that needs of lots of work. I found one of the balusters on the front stairs broken out from rotting clear through and told her I would make a new one. When I went to take some serious dimensions, there were 5 more that really should be replaced because they were close to falling apart.
I bought some white maple and turned the 6 balusters and then noticed that the rails I would be putting them into were also in need of replacement and the other 6 balusters from that side all had bad bottoms .
In short I made 6 new balusters, repaired 6 of them with new bottoms and made 4 top and 4 bottom rails. The rails were a real trip! They had compound angles but I did not take a picture of the set up I used on my cheap B&D miter saw to hit those angles.
The only pics I have are of the completed railing, the primed parts, the setup for spotting the dowel when you are putting it in at an angle and the fixture I made for drilling all the dowel holes in the bottoms of the balusters.
I did a section at a time . I made a board with a rail on it and it had 2 short 2×4’s clamped on each end .I would test cut the compound angle on one of the 2×4’s until it fit and aligned to the spot on the next post. Then I cut that exact angle on the lower rail. Then I would start test cutting the other compound angle on the other 2×4 until I got it to fit just right. I measured that total length and transferred it to the bottom rail and cut the exact angle on it and they fit real nice. I used that all the way around on top and bottom.
I had a marking gauge for the spaces and a drill fixture to put the 3/4” holes in the bottom rails to accept the dowels in the bottom of the balusters. The tops were fastened with 2 Kreg pocket screws each.
The worst part for me was the painting. I hate to paint!! They had 4 colors on each one of them. I put a screw in each end and the mounted them on V blocks made from scrap to be able to turn them and paint the rings in 2 different colors. Only for my daughter would I do this!!
-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!
17 comments so far
SPalm
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#1 posted 09-02-2012 09:17 PM
Very cool. That is a different entry step situation.
Ah, our children and their homes. I have one with a sink falling off of the wall, one with a storm door falling apart, and one with so much work it makes my head spin. The forth one is renting – bless his heart.
I admire your work on all that was required on this one,
Steve
-- -- I'm no rocket surgeon
Jim Jakosh
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#2 posted 09-02-2012 09:29 PM
Yes , Steve, they leave home but there are always ties!! I do like the challenge of doing something I’ve never done before and I do get a lot of it!!
This house has a 12/12 pitch and the chimney needs a cap on it but I’m not going up there!!
............Jim
-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!
jack1
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#3 posted 09-02-2012 09:36 PM
Nice job. You could start a whole new career with this… ;0)
-- jack -- ...measure once, curse twice!
rance
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#4 posted 09-02-2012 09:54 PM
That seems to be the way repairs go. That’s why I don’t like to do repairs. Same thing with furniture repair. Very deceptive as to what is REALLY needed.
On a project like this, I make the recipient do the painting. It gives them something to do, and I TOO hate painting.
Nice job btw. :)
-- Backer boards, stop blocks, build oversized, and never buy a hand plane--
Jim Jakosh
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#5 posted 09-02-2012 09:59 PM
Hi Rance. She is painting the rest of the parts on the staircase. I just did the parts I made…........Jim
-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!
Bob Collins
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#6 posted 09-02-2012 10:55 PM
Lot of work Jim but well worth the effort. Seems nothing is simple in renovating.
-- RIP Bob C, Australia. Your best teacher is your last mistake.
sedcokid
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#7 posted 09-02-2012 11:26 PM
Jim,
Ah yes children, I have replumbed, repainted, rewired and helped with additions. But you know what I wouldn’t take anything for having helped them. There are four and now a granddaughter that has a home, i made her new wood work and a couple of oak thresholds. it is truly a joy to do so. I commend you my friend for helping her. As for your balusters and rails they look great, from the looks of it you must have a duplicator for your lathe or you are really good with a story stick.
Thanks for sharing!
-- Chuck Emery, Michigan,
Roger
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#8 posted 09-03-2012 12:00 AM
Way kool Jim. Looks very whimsical.
-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]
Grumpy
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#9 posted 09-03-2012 12:17 AM
Nice job Jim.
-- Grumpy - "Always look on the bright side of life"- Monty Python
Jim Jakosh
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27710 posts in 4567 days
#10 posted 09-03-2012 12:17 AM
Thanks, Chuck. you know I do have a lathe duplicator but I have never used it. I laid out each one of these and cut them to dimensions each time. I figured it was only 6!

Roger, I should have showed the whole house. it is all in 4 colors, Here, I have one! there is more color in the back. I re made a rotted door frame back there when the glass dropped down. It turned out pretty good.- another challenge!!
-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!
Roger
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21055 posts in 4265 days
#11 posted 09-03-2012 08:23 PM
Really beautiful Jim. My wife wanted to buy a house of this nature, but, while we looked, we never found. We are happy where we are tho.
-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]
Joe Lyddon
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#12 posted 09-03-2012 10:05 PM
Jim,
Beautiful… Just plain Beautiful…
Thank you.
-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: https://www.ncwoodworker.net/forums/index.php?media/albums/users/joe-lyddon.1389/
harry1
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#13 posted 09-06-2012 03:49 AM
How I wish that I could turn TWO identical items let alone SIX! You certainly keep yourself busy Jim.
-- Harry, Western Australia
Blackie_
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#14 posted 09-12-2012 04:24 PM
Nice rails and home.
-- Randy - If I'm not on LJ's then I'm making Saw Dust. Please feel free to visit my store location at http://www.facebook.com/randy.blackstock.custom.wood.designs
mafe
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#15 posted 09-20-2012 10:18 AM
What a wonderful house.
What a wonderful staircase.
But most of all what a wonderful dad.
Jim you are something special.
As always interesting and inovative.
Best thoughts my friend,
Mads
-- MAD F, the fanatical rhykenologist and vintage architect.
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