Baluster Design
Furnished content.
(from WoodNet.net)


I'm working on a staircase project in our home and considering using thedesign linked below for the new balusters. We have an Arts and Craft theme and the LOML and I like the way this looks. Material will be QSWO. I do not have any dimensions on the design of the balustersbut am guessing they are 5/8" to 3/4" thick and the holes look to be ~1/2" square.

Question is: What is the best, quickest and easiest way to make the 4 hole pattern? Obviously there will be quite a number to make, i.e. staircase handrails and bannister on landing/loft area.

Baluster

Options I've thought of:

1) Hollow Chisel Mortiser - I have a Delta 14-651 Hollow Chisel Mortiser and have made some test cuts. The quality of the holes doesn't seem to pass the quality test. A little ragged and some tearout on the bottom, even with a backer board. I'm using the original chisel that came with the unit.

2) Make a "perfect" pattern out of wood, overlaying it on to the work piece. Drill out each square with a 7/16" Forstner bit and then trim the perimeter andcorners with a corner chisel.

3) Considered a router solution (after drilling out primary hole)but not sure bits with bearings would work well enough in such a confined space to be productive and/or accurate.

Is there a better solution I'm not thinking about?

Thanks,

Doug

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