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I was trying to repair a rotted base on my wood porch columns. The columns were sinking into the base and breaking up all of the (so I thought) delicate moulding at the base of the column. I made new bases, but when I took out the column I was surprised to find that what I originally thought to be moulding was actually a circular edge detail on a solid piece of stock. Now the problem: I can recreate the detail on a lathe, but I’m unsure as to what material to use. I think regular 2x material would “chunk off” while turning. I’ve thought of laminating several pieces, crossing grains and using polyurethane glue, but I am unsure of what type of wood to use. Redwood seems too soft, and poplar is not as weather resistant. Any suggestions in material or technique?
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Sam, if I had a nickle for every rotten post base that I have had to replace... Spend a little money and get yourself a nice clean piece of mahogany. Longevity is the key here and you really don't have to worry about turning it if you get a realitivly clear piece. Mahogany is very easy to work with and resists rot very well. Just be sure to put some finish on all sides before you install it.
*Have made replacement bases from Pressure Treated SYP, just hand pick for dense grain. The other material we really like is TREX , usually buy it as round over 5/4 x6 decking and rip the edges off so you get a 1x5 finished piece. You can glue it up with urethanes and turn it into anything you want. Routers love this stuff, and paint loves it too.If you have a lot of rotted bases, have you looked at the cause ? Are the columns ventilated from base to capital, there has to be a way for them to dry out at the bottom, so build a pedestal detail into your new base. If you took the column down and its hollow, try painting the inside as high as you can reach, and let the end grain soak up as much paint as it can.Check the beams the column was supporting, now may be the time to slowly jack them back into their correct alignment, it will help get your columns and details back into place too if you can overjack slightly.b Brian's right......do it once.....for the long haul.
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I was trying to repair a rotted base on my wood porch columns. The columns were sinking into the base and breaking up all of the (so I thought) delicate moulding at the base of the column. I made new bases, but when I took out the column I was surprised to find that what I originally thought to be moulding was actually a circular edge detail on a solid piece of stock. Now the problem: I can recreate the detail on a lathe, but I'm unsure as to what material to use. I think regular 2x material would "chunk off" while turning. I've thought of laminating several pieces, crossing grains and using polyurethane glue, but I am unsure of what type of wood to use. Redwood seems too soft, and poplar is not as weather resistant. Any suggestions in material or technique?