How to Build Stair Spindles

Setting Up

• 1

  Set up the lathe for turning your pieces. Set the first piece of stock on end. Mark diagonal lines with a ruler between opposing corners at each end of the stock. Repeat this step for each spindle.

• 2

  Set the tip of an awl at the intersection of the lines on one end of a piece. Strike the opposite end of the awl with a mallet, driving a hole into the center of the stock. Repeat the step for the other end of the stock. Repeat the entire process for each piece of stock.

• 3

  Line up a drive center for the lathe into a hole at one end of a spindle. Tap the drive center into the hole with the mallet. Repeat the process at the other end of the stock. Mount your spindle onto the lathe at the bottom first. Apply pressure to the bottom as you position the top end to the other end of the lathe.

• 4

  Determine how much of the stock will remain square at the top and bottom. Use a ruler and pencil to mark the shoulder of each square end. Trace a line across each side of the stock where the shoulder of the stock is formed. The shoulder is where the stock will become rounded. Repeat this step for each spindle.

• 5

  Trace the design you want for the spindles on a board as a template. Place the board on the tool rest to follow it. Mark each spindle with the design as you work with it, using the template as a guide.

• 6

  Set up the calipers of the lathe with a fine mill file. Sand the ends with 220-grit sandpaper to gain accuracy with detailing.

Using the Lathe

• 7

  Cut a line with a parting tool 1 1/8 inches to the inside edge of each spindle end. Set the tool handle low to the wood for clear and precise cuts. Start with shallow cuts then deepen the cuts as you carve down to the desired depth. Repeat the step along the outside edge of each end of each spindle.

• 8

  Rough the shape of each spindle out with a roughing gouge to desired diameters. Large diameter contours also use this tool.

• 9

  Set the caliper opposite to the parting tool on the spindle. Measure your critical diameters with the rounded edges and the parting tool. This ensures the spindles are uniform. Keep the piece in contact with the tool rest for accuracy.

• 10

  Stop the lathe frequently while examining each spindle to catch mistakes. Restart the lathe. Add contrast and shadows to the piece with the long tip of a skew chisel pointed downward on the wood.

• 11

  Sand the spindle with 220-grit sandpaper while the lathe is turning.

Attaching the Spindles

• 12

  Find the center of the stair treads with a tape measure. Measure 2 inches on either side from the center and mark the locations. Drill holes in the stair treads corresponding with the ends of the spindles.

• 13

  Install baluster screws into the base of each spindle. Apply a bead of wood glue to each hole in the treads. Set the baluster fastener into position with the driver for the baluster fastener. Set the spindle end with the baluster screw onto the fastener and turn to tighten into place.

• 14

  Check each spindle with a level to ensure it is plumb with the stair tread. Use the tops and sides of the spindles. Adjust the spindles as needed to correct any issues.

• 15

  Determine where the handrail will pass across the top of the spindle. Sloping handrails will require spindles cut to an angle to meet the angle of the handrail. Use a carpenter's square to create the angle on each spindle top. Draw the mark along one face of the spindle top.

• 16

  Cut the spindle with a miter saw along the angle line.

• 17

  Repeat the process used to to attach the spindle bottoms to the stair treads. Fit the handrail over the spindles to attach them together.