simple newel posts

[Ajcoholic]

I do a fair amount of rails and related millwork. Traditionally when a customer wanted square posts, I would make them up as a frame and panel door, with the shaper. Time consuming and subject to movement seasonally, etc.

I noticed that several suppliers of these now make them machined from solid. So when a small railing job came up I decided to try the same technique I used in the past for built up table legs.

I laminated a slab of 8/4 hard maple, and then made a file to cut 5 individual panels from each. I used a profile bit (beading) and a ball end mill to give the bead and cove profile, then an end mill to undercut the face before V carving the faux panels.

It worked out well, as then I just ripped up the individual panels from the larger panel and mitred the edges on the table saw, and glued them together.

Today I filled the corners with 3/4 blocks and started sanding them. I also made up some 3D carved top caps. Should look pretty decent when finished. They will be stained a dark cherry red.

http://i83.photobucket.com/albums/j307/ajcoholic/872d68a4-9a68-494a-bf37-4e2263dee7b7_zpsjvpmuwr0.jpg (http://s83.photobucket.com/user/ajcoholic/media/872d68a4-9a68-494a-bf37-4e2263dee7b7_zpsjvpmuwr0.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_0177_zpsmqfb3ufm.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_0177_zpsmqfb3ufm.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_0184_zpspaxvb2ef.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_0184_zpspaxvb2ef.jpg.html)

http://i83.photobucket.com/albums/j307/ajcoholic/3f458520-3f08-4b4f-a5ec-09f47839c48d_zpsgxd1fbfz.jpg (http://s83.photobucket.com/user/ajcoholic/media/3f458520-3f08-4b4f-a5ec-09f47839c48d_zpsgxd1fbfz.jpg.html)

The panels took me minutes to laminate - set up on the router and held with the vac, and cut out in about 20 minutes per panel of 5. After gluing the posts and half post up I did the file for the caps and they took 50 minutes to carve (rough with 1/2" end mill and finish with 1/4" ball end mill).

Total time is much less than the old way which is more than a full day job for three posts. I estimate these three will take approx less than half that including machine time, which I use to do other jobs.

[JimmyD]

Those look great and save time also, a two-fear!

[scottp55]

Thanks for posting pics Andrew.
Love to follow your projects as you document them so well:)
Congrats on the write up!
Is that a Watco/Deft oil stain again this time? (never use their colors, but should get familiar with them:( )
Recently posted some of your threads on Vectric forum(your Mahogany table/chairs and the Gorgeous Maloof Rocker), because when I said a week before lacquering after oiling, he told me I was crazy(with a smile). Wanted to show him "Top Notch Craftsmanship" takes as long as it takes:)
Great work again!
scott

[Brady Watson]

They look great. Gotta love saving time!

-B

[Kyle Stapleton]

They look nice.
How do you post your pictures in the text area?

[Brady Watson]

How do you post your pictures in the text area?

In order to post pics inline with text, they have to be hosted somewhere like PhotoBucket et al.

-B

[Ajcoholic]

Thanks for posting pics Andrew.
Love to follow your projects as you document them so well:)
Congrats on the write up!
Is that a Watco/Deft oil stain again this time? (never use their colors, but should get familiar with them:( )
Recently posted some of your threads on Vectric forum(your Mahogany table/chairs and the Gorgeous Maloof Rocker), because when I said a week before lacquering after oiling, he told me I was crazy(with a smile). Wanted to show him "Top Notch Craftsmanship" takes as long as it takes:)
Great work again!
scott

Not this time. Im using a glaze-type stain that can be left on as a film (which dries). It's a commercial product designed to be used with post-catalyzed lacquer. I can get a very rich, deep colour unlike oil which is left up to the mercy of what the wood absorbs.

Ill post pics when its done. I should have the railing assembled next week and in the finishing stages. The people are itching to get this done. Its a job I priced out and got two months ago. Im very behind in the shop right now. I have work booked up for probably 6 months... And people say no one wants custom woodwork any more...lol

[Ajcoholic]

In order to post pics inline with text, they have to be hosted somewhere like PhotoBucket et al.

-B

Ive been using photobucket since around 2000 I think. Always worked well for me.

[mtylerfl]

Beautiful work, as usual, Andrew. I love seeing what you're up to!

[Kyle Stapleton]

Thanks for the info.

[Ajcoholic]

I got the rail assembled today (not glued up yet - I will dismantle it on monday and get it stained and in the finishing process)

http://i83.photobucket.com/albums/j307/ajcoholic/cf55d296-343e-40da-a267-3c2c2cfc4950_zpsme5qd4ly.jpg (http://s83.photobucket.com/user/ajcoholic/media/cf55d296-343e-40da-a267-3c2c2cfc4950_zpsme5qd4ly.jpg.html)

I am proud of my shop when it comes to being a true custom shop - we don't buy much (if anything really) in - I mill up my own rail and shoes, turn my own baluster spindles and of course make the newel posts as well.

I also make the patterns for my hydraulic copy lathe on the Shopbot. I enjoy giving each customer their own, unique turning design, that no one else can just go and buy off the shelf. I did three different samples for this customer until they decided on this one.

Here is the custom stain colour I mixed up for the customer. They really liked the dining room table they have and wanted to match the colour. Its a nice, rich reddish-brown.

http://i83.photobucket.com/albums/j307/ajcoholic/4aa742cc-a4da-4578-8e61-1285b2860a83_zpsglfl6qsv.jpg (http://s83.photobucket.com/user/ajcoholic/media/4aa742cc-a4da-4578-8e61-1285b2860a83_zpsglfl6qsv.jpg.html)

And if anyone is interested, we are just finishing up a pretty large stair and railing job started before Christmas as well. Just about an hour left to finish some plugs and clean up. This is a new home - and the stairs and rail are all maple (a mix of natural and black stained) with some metal accents. Unfortunately on this job no CNC was required as everything is square. But it's a nice job. I was a little uneasy when they told us what the colours would be but it suits the home well and looks pretty good - modern and clean but a little bit traditional as well.

http://i83.photobucket.com/albums/j307/ajcoholic/e84aab0a-a88c-44c5-9c05-f248109056ca_zpscpgelf0n.jpg (http://s83.photobucket.com/user/ajcoholic/media/e84aab0a-a88c-44c5-9c05-f248109056ca_zpscpgelf0n.jpg.html)

[Ajcoholic]

Beautiful work, as usual, Andrew. I love seeing what you're up to!

Are you going to be at McGrew's again, Mike? Looking forward to it!

[mtylerfl]

Are you going to be at McGrew's again, Mike? Looking forward to it!

I just faxed my Registration to Jim today! I hope to see you there!

My goodness, those projects you posted are gorgeous.

[Ajcoholic]

I just faxed my Registration to Jim today! I hope to see you there!

My goodness, those projects you posted are gorgeous.

Well I'm registered, got the hotel booked and I am just booking my flights (three connections for me to get from here to there) this weekend - so barring some really bad weather Im there! I hope you are giving a talk again this year.

As for the work, thanks. I try and make my customers happy :)

[dmidkiff]

Andrew, you do awesome work. I really enjoy your posts and like that you are a full custom shop.

[scottp55]

They BOTH look wonderful Andrew, I see what you mean by the stain/glaze. Looks a lot like the 150 Yr old Mahogany used in bed (4 poster from Revere and Sons) I'm lying in:).
Didn't realize you were trying to match an existing piece of furniture:o
Wonderful work! (as usual:)
scott

[Ajcoholic]

Everything stained today. Always looks better when some colour is applied IMO.

WIll post a pic when its together and installed..

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_0200_zpsxbjzxfpv.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_0200_zpsxbjzxfpv.jpg.html)

[blackhawk]

Andrew - Great work as always! I appreciate the help that you gave me on the chair seats also.

[bobmoore]

looks great Andrew. Are you using M&T to connect rails to newels? Bob

[Ajcoholic]

looks great Andrew. Are you using M&T to connect rails to newels? Bob

Im using Zipbolt connectors on the rail, and Lamello Clamex P10 connectors on the shoe.

Since the rail isnt too large once everything is sprayed I will assemble in in the shop and glue everything together (except the short section will be separate from the long section, just connect that at the house)

The Zipbolt fasteners are pretty slick. http://zipbolt.com.au/

The Lamello Clamex, which I just bought a few weeks ago, is also a slick system.

AJC

[bobmoore]

Thanks for the link Andrew. Those look really nice. Bob

[Ajcoholic]

Sorry we finished this up last Friday - forgot to post a photo.

The customer was very happy.

http://i83.photobucket.com/albums/j307/ajcoholic/IMG_0204_zpse107nt7w.jpg (http://s83.photobucket.com/user/ajcoholic/media/IMG_0204_zpse107nt7w.jpg.html)

[scottp55]

Very Nice Andrew!
I take it you were trying to match the stairs?
(stair treads look deadly IF I ever wore Heels:)

[Ajcoholic]

Very Nice Andrew!
I take it you were trying to match the stairs?
(stair treads look deadly IF I ever wore Heels:)

We did the nosings as well. They look narrow but it's an optical illusion the width and nosing protrusion are up to code.

The nosings are thick since they had construction lumber capped with 1/2" ply and then the 5/16 tile.

I didn't do the tile. Just the woodwork. Capping the stringers and the nosings and rail.

[kevin]

Andrew it looks good plus you came up with different technique which is a real bonus solving production problems
I went way over budget on a staircase its not hard to do