Baluster Design

[kencombs]

I can only think of two solutions that would work for me if I had to make a lot of those.

Find that CNC shop.

Fall in love with another design with no square holes.

[Woodenfish]

I can only think of two solutions that would work for me if I had to make a lot of those.

Find that CNC shop.

Fall in love with another design with no square holes.

He could just paint black squares on them which looks like what was done on the end post. On a practical note it would make sanding and finishing so much easier and it sure would be simpler to keep clean without the hassle of getting all of the dust out of those little holes.

[Tapper]

He could just paint black squares on them which looks like what was done on the end post. On a practical note it would make sanding and finishing so much easier and it sure would be simpler to keep clean without the hassle of getting all of the dust out of those little holes.

Unless I'm badly mistaken the 4 holes in the "birdbox" in the photo may just be a slightly larger version of the ones on the balusters. Painting "faux" black squares on the balusters is not the look I'm going for. All the wood on this staircase project is going to be QSWO.

If the CNC plan doesn't work out, I have a couple of other options I'm considering - stay tuned.....

Doug

[FrankAtl]

Seems to me like buying a new chisel for the hollow chisel mortiser is the most obvious solution. The baluster design seems to be made for that tool.

[MGoBlue1984]

Hone the outside and sharpen the interior edges.

[Tapper]

Seems to me like buying a new chisel for the hollow chisel mortiser is the most obvious solution. The baluster design seems to be made for that tool.

This would certainly seem to be a plausible possible solution. Lee Valley carries a line of hollow chisel mortising units that are made in Japan and may be a better "breed of cat." I've considered that option and may buy one. Concern is that if the chisel does cut a clean square hole, will the bit wander to one side (as many do, including the one that came with my mortiser) and create an oval on one side? 

As I said earlier, that would be a deal breaker.

Doug

[Tapper]

Hone the outside and sharpen the interior edges.

Good suggestion on both. I've bought a set of those conical hones and used them to sharpen the interior edges. Haven't honed the outside of the chisel yet. As I said earlier, the one I have is cutting that oval on one of the edges of the square hole. This is the first time I've used a hollow chisel mortiser and my research online reveals that setting the depth of the bit seems to be"fiddly" at best.

So of course there is a possibility of operator error. :)

Doug

[Tapper]

Another option I'm considering is rather than the 4 holes shown in the example I linked, using the traditional faceted plugs to fill blind, rather than through holes. Both Lee Valley and Rockler sell square chisels that are designed to be tapped with a hammer to make the square hole. Using this design I would only install the plugs on the "show" side of the baluster, not the interior where the step treads are.

There is a real good video online showing how to make the faceted plugs on a miter saw pretty quickly, relatively speaking. These plugs are typically made from ebony, which is pretty pricey. I do however have quite a supply of walnut cutoffs that would probably work OK, especially since I plan to use a natural finish on the oak; no stain. The walnut would probably provide enough color variation for effective contrast.

Doug

[FrankAtl]

"Concern is that if the chisel does cut a clean square hole, will the bit wander to one side (as many do, including the one that came with my mortiser) and create an oval on one side? "

I've never owned or used a hollow chisel mortiser but I would think one set up correctly and with a decent chisel would work. Are the benchtop ones like you have known for wandering?

[Woodenfish]

Unless I'm badly mistaken the 4 holes in the "birdbox" in the photo may just be a slightly larger version of the ones on the balusters. Painting "faux" black squares on the balusters is not the look I'm going for. All the wood on this staircase project is going to be QSWO.

If the CNC plan doesn't work out, I have a couple of other options I'm considering - stay tuned.....

Doug

I can’t imagine what a bunch of kids would be stuffing into that bird box if those holes were real. Looking at the picture it didn’t appear like those holes were actually open.