How to Replicate Antique Staircase Balusters

Ornate staircases—particularly those in older homes—can be difficult to repair. Their intricate and custom designs are difficult to replicate, often taking a true craftsperson to create a match for balusters and moldings.

This Old House general contractor Tom Silva is just the person for the job, and in this video, you can watch him help a Queen Anne homeowner replace a baluster with a hand-carved replica. 

In the guide below, we’ll walk you through how to do the job yourself, from the hand-turning process to installation. You’ll need to have skills with a lathe, something the average DIYer can’t expect to master quickly. But it’s worth taking a look at what’s involved in creating these beautiful, unique details.

What Are Balusters?

Balusters are vertical supports that hold up the handrail of a staircase. They often feature intricate designs, including rope-turned details and ornate profiles. These elements contribute significantly to the overall aesthetic of a staircase and can be a defining feature of a home’s interior. The entire structure of balusters running up the staircase is called a balustrade.

Sometimes balusters are referred to as “spindles,” but spindles are a specific type of baluster. Spindles are thin and turned on a lathe, meaning they’re typically more ornate than other types of balusters. The balusters that Silva creates in the video are spindles, but the replacement process is useful for all types of balusters. Thus, we’ll use the term “baluster” to encompass both the plain and decorative versions.

Preparing to Replicate Antique Balusters

Before beginning the replication process, gather the necessary materials and tools. 

Materials

• Wood blank (matching original wood type if possible)
• Manila paper
• Landscaping string
• Tape
• Sandpaper (220 grit)
• Wax-free shellac
• Gel stain
• Dowel

Tools

The list includes specialty tools you may not already have in your workshop.

Step-by-Step Guide for Baluster Replication

The bulk of the video above shows Silva installing the new baluster, but at the end of the clip, you can see some of the hand-turning process. That’s what we’ll walk through next.

Step 1: Creating a Template

The first step in replicating an antique baluster is creating an accurate template. This process ensures that your replica will match the original as closely as possible.

1. If possible, remove an existing baluster from a less visible location to help you create a template.
2. Use manila paper to create a profile template of the existing baluster.
3. Hold the paper against the baluster’s edge and use scribes to mark the top and bottom profiles.
4. Mark where the top and bottom sections begin and end with a pencil.

Step 2: Turning the Baluster

With your template ready, it’s time to begin turning the new baluster on a lathe. These steps will walk you through turning the top and bottom sections.

1. Chuck the wood blank into the lathe.
2. Mark the endpoints of the top and bottom sections using a chisel.
3. Round the section between the marks using a skew chisel. Move the chisel back and forth, taking small bits off at a time until the blank is round between the marks.
4. Stop the lathe. Place the existing baluster next to the blank and mark the blank at the high and low sections. Each mark signifies the end of a transition or the high and low points of the curves. 
5. Turn on the lathe and hold the pencil at each mark to continue the mark around the baluster.
6. Use chisels to cut the different profiles according to the template and the marks drawn on the blank. 
7. Check each section with the calipers to ensure that they’re the same diameter as the existing baluster. 

Pro tip: Start with the deep sections and then move to the rounded sections, switching chisels as needed and using the template and baluster for reference. Repeat the process at both ends.

Step 3: Creating the Rope Detail

The baluster in the video is especially challenging to replicate because of its intricate rope detail. This step requires deep experience with wood turning, and you’ll likely want to practice on scrap wood. Take your time with measuring and marking before you start cutting.

1. Round over the rope section with a skew chisel.
2. Divide the rounded section into three equal segments.
3. Draw a straight line down the length of the rope section at these marks.
4. Hold the existing baluster in place and mark the deepest part of each section of rope onto the baluster blank. 
5. Mark the baluster all the way down, and finish marking it all the way around at each mark by holding the pencil in place and turning the baluster.
6. Starting at one end of the rope section, place the end of the string where the first mark and one of the lines meet, taping the edge in place. 
7. Twisting the baluster, place the string at the next intersection, then the next, and so on, until the string spirals down the entire length of the rope section. 
8. Trace the string with the pencil. 
9. Remove the string, move it to where the first mark and the next line meet, and repeat the process. 
10. Remove the string and do it one last time, marking the entire baluster with three spirals.
11. Score each spiraled line to the appropriate depth with a backsaw.
12. Use a coarse rasp to grind away the wood along each spiral. Continue grinding until the rope section is mostly rounded.
13. Smooth the rope section with sandpaper.

Step 4: Finishing the Baluster

The final steps involve matching the finish of the new baluster to the existing ones.

1. Apply wax-free shellac with a rag to even out the different textures.
2. After 10 minutes, sand the baluster with 220-grit sandpaper.
3. Apply gel stain to match the color of the existing balusters.
4. Allow the stain to dry completely before installation.

Step 5: Fitting the New Baluster

Once again, take your time with measuring and marking so you’re sure of the dimensions by the time you cut the replacement baluster.

1. Measure the length of the top sections of the existing balusters where they meet the handrail on the upstairs (e.g., tallest) side.
2. Hold the new baluster into position at the mark to ensure the top section lines up with the existing balusters.
3. Ensuring the spacing between the old baluster and the new is correct, use a pencil to mark the angle where the baluster meets the handrail.
4. Follow the mark you made with a coping saw. Note that this is a rough cut, and you will fine-tune it later.
5. Mark the spacing between balusters on the handrail and the stair tread.
6. Measure from the mark on the handrail to the tread to find the height of the baluster.
7. Mark this height measurement on the new baluster, which will give you the length of the base section.
8. Use a hand saw to cut the baluster to length at the base.

Pro tip: If you prefer, you can also use a sliding T-bevel and a miter saw to find the correct angle for the top of the baluster, as outlined in our guide to replacing balusters.

Step 6: Installing the New Baluster

Once your replica baluster is complete and the finish has dried, it’s time to install it.

1. Test-fit the baluster to ensure the bottom sits flat on the tread and has equal spacing with neighboring balusters.
2. Use your saw or a block plane to make minor corrections if necessary.
3. Drill a hole in the baluster’s base to hold the dowel.
4. Insert the dowel, press it flush with the base, and slide the base into place, allowing the dowel to drop into the hole in the tread.
5. Shift the baluster’s top into position and secure it with screws.
6. Check that the new baluster aligns correctly with the others in the staircase and make any necessary corrections.
7. Touch up the areas around the screws with wood stain.

Maintaining Antique Balusters

Antique staircases have a special charm. To preserve their beauty, regular maintenance is key. Careful attention ensures both original and replicated balusters remain in excellent condition. Here are a few tips for maintaining antique balusters.

• Dust regularly with a soft cloth to prevent buildup.
• Clean gently using a damp cloth to remove surface grime. Avoid using harsh chemicals that could damage the finish.
• Apply a thin coat of furniture wax annually to protect the finish and enhance the wood’s natural luster.
• Inspect the balusters periodically for loose fittings or signs of damage.

• Avoid direct sunlight on the staircase to prevent fading.
• Consult a professional for repairs beyond basic maintenance.
• Use felt pads under furniture near the staircase to prevent scratches if they get moved.

Additional Techniques for Replicating Intricate Details

When replicating antique balusters, it’s important to be well-versed in various woodworking techniques. Some intricate details can be particularly challenging and may require specific methods to achieve exact replicas.

Use Proper Lathe Tools

Here are the tools Silva used during the various steps of the hand-carving process.

• A parting tool for low points of the spindle details
• A spindle gouge to carve into tighter areas
• A skew chisel to carve into the larger areas of the spindle and to round out the edges
• A hand saw to cut slots in the spindle following the traced-out lines from the string
• A rasp to file down the edges of the saw cuts until each section has a rounded edge

Using a Duplicator

If you’re not an experienced woodworker, there’s a shortcut that will allow you to copy the profile of an existing baluster: a lathe duplicator. The manual type used by hobbyists is a tool that you hold in one hand while turning the wood, with one end pressed against the existing baluster and the other against the wood blank. You can purchase a pre-made duplicator or follow instructions for creating your own. 

Unfortunately, these duplicators can only copy profiles, not intricate details like the rope design on the baluster in this project. However, if your project doesn’t have these details, and particularly if you need to make several identical balusters, a duplicator may be worth using.

Achieving Precision in Turning

Precision is key when turning the baluster on a lathe. Here are some tips for better results.

• Use calipers frequently to check measurements against the original baluster.
• Take your time with each cut to avoid mistakes.
• If you have difficulty seeing the project against the backdrop of your workshop, put a white piece of paper or artboard behind the piece, securing it with tape or magnets.
• Seek guidance from experienced woodworkers if you’re new to lathe work.

Challenges and Solutions

Replicating antique balusters can present several challenges. However, with careful planning and problem-solving, these challenges can be overcome.

Matching Wood Types

Finding the right wood type is essential for an accurate replication. Identify the original wood species used in the balusters, and source wood from specialty lumber suppliers if necessary. If an exact match is unavailable, you may have to try using wood stains to match the color and grain pattern.

Custom Stains and Finishes

Matching the stain and finish of the new baluster to the existing ones is nearly as important as the carving if you want a seamless look.

• Test different stain colors on a scrap piece of wood before staining the new baluster.
• You may need to combine colors and apply multiple coats to achieve the desired shade.
• Use a finishing oil to protect the baluster and enhance its appearance.

• Experiment with different finishing techniques on scrap wood.
• Apply multiple thin coats of finish for a smooth, even look.
• Allow adequate drying time between each coat to prevent smudging.

Ensuring Safety and Compliance

No matter how much time and effort you spend replicating the look of an antique staircase, it’s more important that it meets current safety standards and building codes. This not only preserves the aesthetic value of the staircase but also ensures its functionality and safety.

Building Code Requirements

Most building codes specify the maximum allowable gap between balusters to prevent accidents, especially in homes with children.

Measure the existing gaps to see if they are compliant with local regulations. Adjust the placement of new balusters if necessary to meet these requirements. You can consult with a building inspector for guidance on local codes.

Apply a fire-retardant finish to the new balusters if required by local regulations.

Structural Support

Antique staircases may have weakened over time, requiring additional support during the replication process.

Reinforce weak areas before installing new balusters, and use high-quality materials and fasteners to ensure the stability of the staircase. After installation, test the stability of the new baluster by applying gentle pressure. Reinforce as needed.

Our Conclusion

Woodworking is a skill that takes years to master. For some DIY enthusiasts, this may be an exciting challenge; for others, it’s an obstacle to working on intricate pieces like this antique staircase. You may need to consult an expert like Silva to replicate something as detailed and unique as this balustrade, but you can often install it yourself.