Step 5: Cut the Hole

Cut the Hole for how to Build a Gingerbread Balustrade
Photo: Anthony Tieuli
«»
With the blank still secured in the jig, use a drill/driver fitted with a hole saw to cut out the decorative hole. Unscrew the template, swap in a fresh blank, screw the template back down, and rout the blank. Repeat these steps to make all your balusters, then lay them out on your work surface with the patterns aligned. Mark a final length on each one, and use a miter saw to trim them to size.
Ask TOH users about Porch

Contribute to This Story Below

    Tools List

    • jigsaw
      jigsaw
    • drill
      drill/driver and bits
    • 1/8-inch bit with combination countersink
      combination countersink bit
    • hole saw
      2-inch hole saw
    • miter saw
      miter saw
    • router
      router
    • router bits
      -by-2-inch straight router bit with -inch collar
    • random orbit sander
      palm sander and 180-grit sanding pads
    • 2½-inch angled sash brush

    Shopping List

    ½-inch plywood Get one 2-by-4-foot sheet for the template.

    ¾-inch plywood Get one 2-by-4-foot sheet for the jig base.

    ½x5 pine Get six 16-footers for the balusters.

    2x4 primed straight-grain Douglas fir bottom rail Get two 8-footers.

    2x4 primed and chamfered Douglas fir handrail Get two 8-footers.

    1x2 primed pine Get four 8-footers for the nailing strips.

    wood glue

    2-inch wood screws

    1½-inch stainless-steel screws

    2½-inch stainless-steel screws

    exterior latex primer

    exterior latex paint

    5/16-inch spacers