February 20, 20179 yr Popular Post Building a box newel. After milling the boards down to 3/4" I ran them through the table saw using a power feed, to miter the edges at 47degrees. The outside dimension of the newel is 5", the inside is 3.5". I then glued 3 blocks about 3 3/8" to the inside and secured them with small glue blocks, (just scraps cut about 3/4"×3/4") After the glue sets up, apply glue to 1 mitered edge and use pin nails to hold it in place. Then using shims square the 2 peices to each other, and apply glue blocks to the 3 3/8×3 3/8 inner block to hold it square, and apply glue blocks to the inside miter to hold it together. Now the two sides are square to each other, repeat the process for the 3rd side. Install more glue blocks to the remaining 2 miters, hold the glue blocks down from the inside of the miter about 1/16". Let the glue sets up and use glue on the 2 remaining miters, and construction adhesive on the glue blocks, the adhesive will fill the small gap. Put the remaining peice in place and clamp it up, and let set overnight to dry. My experience tells me that construction adhesive expands as it dries resulting in open miters on the last peice if not clamped. On the top of the newel I add 1 1/4" backing on all 4 sides, this is where the rail be secured, 2" of wood is stronger than 3/4". Make a top block to your liking, and trim it to your liking. Sorry for my inability to post the directions with the appropriate picture, I'm a man and don't read directions and tutorials. This newel is already notched for the stairs, that's why the cuts on the bottom. Edited December 7, 20178 yr by Ron Dudelston tags added
February 22, 20179 yr Author Nick, All that matters in this newel is that the outside of the miters are tight, the inside of the newel will not be seen so the inside of the miters don't really matter, the glue blocks hold the miters together, and not the miter joint itself. Better to over miter than under miter and have a gap on the last joint. Tried to post a pic for you but the system won't allow me to do that. Any help from the moderators??
February 22, 20179 yr 11 hours ago, Kenny Tarmack said: Nick, All that matters in this newel is that the outside of the miters are tight, the inside of the newel will not be seen so the inside of the miters don't really matter, the glue blocks hold the miters together, and not the miter joint itself. Better to over miter than under miter and have a gap on the last joint. Tried to post a pic for you but the system won't allow me to do that. Any help from the moderators?? Gotcha...thanks...
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