I have already rough cut all the round banister
rail sections out of straight 2"x12"x12' pressure treated board.
Here I am attaching the old rail to the new rought cut one to shape
the
it.
Fig. 2
I then flipped
the pair over and with a special router bit I can shape the new rail
to a closer match of the old
one.
Fig. 3
Because all
the boards are different thickness I have to send them through the
planer. This step takes out a lot of the lumber yard damage and
abuse to the boards. It also cut down on sanding
time.
Fig. 4
I am using glue and counter to hardware to secure the rail
peices together. The rails measures nearly 18
feet.
Fig. 5
Now I am sanding to the final
shape. I am squaring off the sides and blending in the
joints. Once the sides are done then I will give the top and
bottom a once over before the final
sanding.
Fig. 6
Here veiwed
upside-down is the top rail. I used a roundover bit
and set the depth to give it a shoulder. I did this only
for the top rail. I used the same roundover bit and
set the depth
so there is not
sloulder.
Fig. 7
I have filled in the joint splices with super
hard wood filler. Probably because of the rain and the amount of
wood filler it is taking longer to cure out. Once it is cured out I
will sand it smooth. I might have to touch it up with more after
shrinkage.
Fig. 8
Here is an overall veiw of both top and bottom
rails. I hope to be priming them soon. Now I must wait for it to
cure.
