Replies

1. 
   JeffBuck | Dec 11, 2004 02:54am | #1

   mortice bit ...

   round drill bit and a chisel ...

    

   or sharpen the balusters and drive them home ....

    

   Jeff

     Buck Construction 

      Artistry in Carpentry

           Pgh, PA

2. 
   ScottMatson | Dec 11, 2004 03:17am | #2

   Or buy stair parts made for this. They've got a "square" groove in them, you put the baluster in, and insert a thin piece of wood between them. Finished, it looks like continuous molding. Simple.

   Another thought would be to rip the rails lengthwise down the middle, and make the mortises on a table saw or radial arm, and then glue, clamp and nail them back together prior to installing the balusters.

   You could also drill out the holes and use a corner chisel to make nice square edges.

   
   

   ---

   Edited 12/10/2004 7:19 pm ET by Mad Dog

3. 
   allenschell2 | Dec 11, 2004 03:44am | #3

   Another option is to drill the apropriate round hole and use the little boots on the bottom and top. They make them for incline and level and they have little set screws, saves a ton of time and looks good.

1. 
   MisterT | Dec 12, 2004 05:33pm | #6

   This is probably what he needs!

   Got any links/info/manuf. ???

   Thanks 

   Mr T

   I can't afford to be affordable anymore

1. 
   allenschell2 | Dec 12, 2004 06:00pm | #7

   I'm sorry I don't but just the other day I saw a post w/pics of the exact thing, I'll see if I can find it.

2. 
   allenschell2 | Dec 12, 2004 06:18pm | #8

   T, here's one I googled....
   http://www.stairsupplies.com/index.asp?PageAction=VIEWCATS&Category=66

   Edited 12/12/2004 10:19 am ET by ALLENSCHELL2

4. 
   DougU | Dec 11, 2004 06:29am | #4

   I don't know if this would be a continuation of what Maddog was saying but..........

   Couldn't you plow a dado down the center, install your balusters.  fillet in-between balusters.

   If you want to get real complicated you could always drill a hole with a mortise machine, the trick will be to hold the railing at the appropriate angle, but I think you can do it.

   Doug

5. 
   RW | Dec 11, 2004 06:47am | #5

   I think Allens got it. I've never even hear of it another way with wrought iron ballusters. Lay it out, drill your bottom hole a consistant depth. Your spacing between the bottom board and the rail bottom should be 1" under the overall balluster length. Bore the top hole into the rail just over an inch in depth. The bottom and top rounds on the ballusters we get have different sized diameters. That I could see varying from one place to the next. But there's a rationale. A 1/2" spade bit leaves just a little room at the top, and fits pretty snug at the bottom. Put the balluster in with the square cap on the bottom, lift it into the hole, and push down hard to seat it. Tighten the set screw.

   I've seen some try to epoxy the tops to keep them from ever getting loose. Good principle, but pretty messy in practice.

   Or, you could get a mortising machine and build a jig that holds the board at the rake angle, but what a PITA. Biggest challenge would be getting the bit to guide straight hitting the board at an angle like that. It would want to walk.

   "If you pick up a starving dog and make him prosperous, he will not bite you. This is the principal difference between a dog and a man." - Mark Twain