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Creating a Gingerbread Railing

Bob meets Ryley outside the Victorian style house in Massachusetts to help him with the railing. Ryley starts with two by six vertical grain fir for the top railing and routes out a ridge for the balusters and applies standard moulding to the sides. Bob and Ryley head back to the workshop to create the balusters. Ryley traced the pattern from an antique baluster to create the design to create a form. They trace the pattern onto individual pieces of wood and cut out the pattern with a band saw and scroll saw. The meticulous hand cutting is what leads to the beautiful antique pattern. Back out at the site Ryley shows Bob a tip for dealing with the quirkiness of antique wood. He builds a template by scribing the angle on scrap wood then cuts the railing using this form. Bob uses sugar pine for the corner angles.
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Creating a Gingerbread Railing

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" Well, last week, we just about finished framing all of the porch and now we've got a roof over our heads here and you're trimming it."

" That's right."

" This looks really good."

" Now, how did you make this railing?"

" This was a piece of 2 X 6 vertical grain fir. We just took a three-quarters out of the center of it with a router."

" Uh huh."

" And then we applied a 1-inch half round to either side so the detail on it."

" That's just a molding that's nailed on."

" Yeah."

" And then the balusters, I guess you call them."

" Yeah."

" Are just let into the top there, huh?"

" That's right. It's pretty simple."

" And they look pretty good."

" Goes right up in there."

" Give it a couple of taps. Yeah. Very nice. And of course it's handwork so you're really kind of creating a different kind of look. If you just look at half of this individually, looks a little bit like a pineapple. When you put them all together, you're creating kind of a floral motif and if you wanna see how we cut these out in the workshop, take a closer look."

" So, Riley, this is gonna take a long time to do. What's the first step?"

" The first thing I've done is take this piece of plywood up to the railing and trace out what was already existing there."

" So we're copying that detail?"

" Right."

" And then you cut this out?"

" This is our template, right there that we'll be going from, okay, we'll just take that and place it on these 1 X 5, 1 X 6 rather."

" Okay, and then how do we actually cut out the form?"

" Well, this little keyhole in the middle we'll do with a hand drill, just run the drill through until the point comes through the other side."

" Yeah, you don't wanna go all the way through. If you do all the way through with your drilling, you can always count on doing that, but if you only pierce the other side of the wood and then come back with the same bit, you can count on getting nice clean hole on both sides."

" We'll be doing 90% of this need to be cut away on the band saw."

" Okay."

" So, I'll just come right over here."

" Here we go, just needs a little sandpaper and it will look great. How many of these do we need?"

" About 35 to 40."

" Oh, we better get busy."

" Any time you re-use antique building materials with new wood, you're apt to find a little quirkiness and in this case our post, which is nice and square up top, when you get down to the bottom, you'll see that it's twisted along the way, a full half inch in just 5 inches. And, we've gotta cut a top rail here. We wanna make sure we don't make a mistake."

" That's right. We're gonna cut it one time."

" So, we're creating basically a jig."

" Right, or a template."

" Or a template."

" And this is some leftover stock that we're using."

" Uh huh."

" I'll just place that up there and--"

" Transfer that angle on to a piece of stair wood."

" Place that right up against the post and scribe it. Right there. Now, we'll just cut that."

" Okay. Now, we tack this on here and that will be our guide."

" That's it."

" That's our guide for cutting the actual railing."

" Alright. Let's see how this came out."

" Looks good."

" Perfect fit. Let's get those balusters on."

" Okay, now you wanna start from the middle and go towards the end so that they'll be evenly spaced when you get there."

" Okay, that's the finishing touch."

" Okay, thank you."

" On the top of the porch post. Now, Riley, that's made out of sugar pine."

" That's a sugar pine, that's right."

" It's really a real clear white pine and did you cut it just on the band saw?"

" Band saw and the saber saw."

" And now some more of those 6 penny galvanized finish, and we've got a Victorian corner."

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