How to Make a Wooden Recessed Panel Newel Post for Outdoor Railings

Tuesday, August 21, 2007

Steps

Cut the 6 x 6 post and 8 pieces of lattice to 34" in length.
Now rip (cut the pieces long ways) 4 pieces of your lattice to 1 1/4" wide and 4 pieces to 1" wide. Its best to cut a little off of each side of the board to make the edges as straight as possible.
Now label each side on the bottom of the post. Each side should be labeled with consecutive letters A - B. One letter per side.
Sand all pieces.
On sides A and C, attach the 1" wide pieces of lattice, using wood glue and nails, so that the lattice is flush with the outside edges of the 6 X 6 post.
Now on sides B and D, attach the 1 1/4" pieces of lattice so that the edge of the pieces you are attaching extend out to the edge of 1" lattice pieces you just attached on sides A and C. In other words, the thin edge of your 1 1/4" lattice pieces should be a flush 90 degree angle with the 1" lattice pieces you just installed.
Measure the width between the vertical pieces of lattice at the top of the post and cut a small piece of lattice to fit snuggly in the space. Attach with wood glue and nails so the top edge of the lattice is flush with the top edge of the 6 X 6 post. Repeat for each side of the post.
Now, while your post is standing upright, place the 1" X 4" board on the ground immediately next to the post. Mark where the top of the 1" X 4" board reaches on your post. Measure 1/8" down from the mark you just made and, using a straight edge, extend a level line around on all sides of the post.
Measure the width between the vertical pieces of lattice where you just made that line. Cut a small piece of lattice to fit snuggly in that location. Attach with wood glue and nails so the bottom edge of the lattice touches the line you just drew around the post. Repeat for each side of the post.
Make sure to sand all cut pieces.
Now measure the width of the post plus the installed lattice on side A of the post. Cut the 1" X 4" board to length. Repeat for side C of the post. Make sure to label the cut pieces with the same letter of the post they are to be installed on.
Now place the pieces of 1" x 4" you just cut next to the appropriate sides of the post as if they were nailed in place. Measure the width of the post plus both 1" x 4" pieces on side B. Cut a 1" x 4" piece to length. Repeat for side D of the post. Label these pieces as well.
Since this post is going to be outside, I chose to cut the top of th base skirt at and angle so that water will run off and for a little extra decoration. You can do the same if you wish to or just leave the boards the way they are.
Do not attach the base skirt to the post yet.
Again, sand the cut pieces smooth.
Cut a perfectly square piece of 2" x 8" wood. The finished dimensions should be around 7 1/2" square.
Again, I chose to cut the edges of the cap at and angle for water run off and decoration. You can choose to do the same or leave the board alone.
Now sand smooth and attach the cap to the top of the post with wood glue and nails. You can use deck screws if you prefer.
Take the post and base skirt pieces to the desired installation location.
Position the post as desired and attach the 4" L-brackets. Attach one on each side of the post and then to the surface the post is resting on. It is usually best to use screws for this.
Now place the base skirt pieces on their respective sides of the post and attach using wood glue and nails.
Now that everything is put together you can fill in the nail holes and stain or paint the post as desired.
One tip is to make sure to address all gaps or areas that will allow water to enter. I actually used caulking to plug most of those gaps. If you do it correctly you won't even know the caulking is there.