Replacing post caps on deck (Not really woodworking, but it's close enough)

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Blog entry by sawdust66 posted 06-17-2022 10:02 PM 466 reads 0 times favorited 2 comments Add to Favorites Watch

So the post caps that were installed on my deck 10 years ago, are garbage. Cheap plastic, that were already deteriorating 2 years in. One of those projects that needs to be done, but gets pushed back. So started tackling it recently. Was going to build my own, but the pressure treated ones at HD were surprisingly decent, and since these will be painted anyway decided to buy instead of build. Saved me a ton of time. So finished them with 3 coats of Sherwin Williams exterior SuperPaint, and 2 coats of Total Boat Halcyon. Will be interesting to see how these hold up. One of my challenges is that the posts are not a standard 4×4 or 6×6 size, since they are 4×4’s wrapped with Trex (generic HD equivalent). So the outside dimension is 5×5. So, using the 6×6 size post caps from HD, I had to make 1/4” shims on each inside face to fill it out. I’m attaching these with some construction adhesive on the top of the post and then 16 gauge nails on all sides. So far seems to be working as expected:

The next hurdle, which I new about is that the builder didn’t cut all the posts evenly at the top. So I’m going to have to fix some of those. Here is an example:

OK, so the bottom caps had gone on fine, no issues, but when I took off the ones at the top of the deck I found this:

So there is no wood to shoot the nails into. I can deal with this, was just unexpected. Really have no idea, why he cut these short, when the first 2 were not. So need to get some 4×4 tomorrow to fill these gaps. So hopefully tomorrow I can get all this done. Thanks for listening.

-- Chris, Pennsylvania

2 comments so far

View JCamp's profile


1790 posts in 2042 days

#1 posted 06-18-2022 04:49 AM

With the sticker at the top of the 4×4 in that last picture my guess is he just used a post that was to short. Either by choice to save a few bucks or because that’s all he had on hand without going back to the store. Easy enough fix though. They are looking good.

-- Whatsoever thy hand findeth to do, do it with all thy might

View TheSnekkerShow's profile


39 posts in 876 days

#2 posted 06-19-2022 02:06 AM

That reminds me, my deck is rotting. I’m curious how well the Halcyon over paint will hold up. It certainly looks good. I’ve only used it over clear epoxy.

-- Ben --

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