Baluster Creation


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Old 03-24-23, 07:28 PM
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Baluster Creation

The white baluster in the pic is damaged and needs replacing. I need to create the white baluster dimensions and re make it from the unfinished one. So I have to cut some off the square off the white one and attach it to the unfinished one. What is the best way to do this?


 
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Old 03-25-23, 02:17 AM
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Cut off the bottom to the correct length and drill and insert a dowel. Or fill the corresponding hole on the tread and use a double threaded screw. https://stairpartsusa.com/products/c...SABEgI2rfD_BwE
 
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Old 03-25-23, 06:44 AM
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OK thanks. This makes sense. The white baluster already has a center hole, so I'm good with that one to start. But to get a center hole in the unfinished baluster...what is the best way? I figure that if I'm off by even a hare, without machinist's precision, they won't line up square when screwed together.

My current thinking goes like this: I start by drawing an X on the cut end, and drilling at the intersection? But if my drill bit isn't perfectly level....?


 
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Old 03-25-23, 06:57 AM
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With a wood dowel I'd drill the hole a little oversized and rely on glue to take up the slop as you get it aligned, with a screw you'd have more leeway.
 
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Old 03-25-23, 07:23 AM
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You would be better off making the joint where the square becomes round. Any slight misalignment there will be less noticeable than square-to-square.

Tom Silva showed something similar for a Newell post in a recent episode of TOH. Here is a link to another article.
 
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Old 03-25-23, 10:30 AM
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If you need the top part of the unfinished one to be the same as it is now, just cut it off a couple inches long. Then cut a section of the white one off. Glue the white section onto the cut end of the unfinished one. Then glue the part you cut off the top back on.

I get the impression straight cuts might be easier for you. Use a long clamp to clamp the pieces together.
 
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Old 03-29-23, 07:46 PM
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Everything has worked out well, thanks for the tips. I did use a dowel plus glue with an oversize hole for easier line up.

I have another baluster repair to do, so speaking of glues I was using 2 part epoxy which is perhaps over kill, but, I ran out of it. I do however have a caulk tube of 2 part masonry repair epoxy, which appears to be a similar material.

Would there be any reason I can't use this this on wood repair?
 
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Old 03-30-23, 08:00 AM
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This is what I need for the other baluster repair. Any suggestions to make this happen? It's at the very top and the pieces are about 5/8" thick.


 
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Old 03-30-23, 08:43 AM
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Replacement would be best but if you need to reuse it, a small dowel and a lot of glue will put it back together. Be sure to take a damp rag and wipe off any excess glue so it won't interfere with the paint job.


If necessary smearing some joint compound over the dried glued up joint and then sanding when dry should make the repair disappear.
 
 

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