Cut stock to length

Step 5:

With the pattern selected, cut the stock to length with a power miter or table saw.

Trace from pattern

Step 6:

Trace the pattern onto the stock material and be sure to avoid any knots. Normally a pencil works, but for pressure treated a permanent marker is better.

Set guard height

Step 7:

The scroll work is best done using a scroll saw.  As our design did not have small radii cuts, we were able to use a band saw using the 1/4" blade.  With the saw off, set the blade guard height to be about 1/4" above the stock and be sure the tension is correct. 

Cut away smaller sections

Step 8:

Start by cutting away smaller sections from one side.

Continue to cut away

Step 9:

Then the other side.

Continue with larger sections

Step 10:

Cut out the larger sections.

Secure strap

Step 11:

Removing the small sections carefully.

Hand sand

Step 12:

Finish sanding by hand, or by using a trim or drum sander.

Secure bottom railings to post

Step 13:

The hand and shoe rail can be made of 2x4, 2x6 or 5/4 stock.  We used 5/4 fir for the base of the shoe rail. The hand rail is two pieces, cut from 2x4 and 5/4 stock with an angle and beveled on the top.  Both rails must be securely fastened to the post.  Note that this must be very strong to support the lateral weight of over 200 pounds.  This can be accomplished through a series of screws.

Shoe railing for baluster

Step 14:

The balusters slide into the mortise in the shoe rail.

Screw in shoe railing

Step 15:

It takes several hands to to this done, so get some help on this.  On the last baluster, you will need to rip the width to fit. Once in place, secure the rails with weatherproof screws every 18 inches.

Secure connector with a screw

Step 16:

Once you have the railing in place, use a good quality primer and follow with two coats of paint for the final step.

Reference:

You might also consider purchasing the book Ornamental Carpentry by Ben Knapp for more design ideas.

   Uncle Johns

   Victorian Millworks

   Mad RiverWorks

   Cumberland Woodcraft

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