Here's the weekend report with lots of pics.
I've been trying to tackle the lip under the bullnoses and steps.
I scrapped the concept of ripping 1x2 routed oak pieces. The table saw just couldn't grind through it and it was a lot of work. So after scrapping a few 8' pieces. I picked up some unfinished oak base shoe 1/2" x 3/4". This gave me a standard step height of 3/4" step and 1/2" lip...so a total of 1 1/4". I would've liked it at 1 1/2" but like I mentioned...scrapped that idea.
So I thought I'd practice on a stair. Just in case I messed up.
Started by routing the top with a 1/2" roundover bit. Does anyone know if the $30 carbide bits are better than the $3 bits? I went with the $3 bit and it seemed to work through it alright.
I ran the router straight past the edges to give it a sharp look rather than rounded.
Snapshot of the trusty Porter Cable Brad Nailer:
I flipped the stair over and glued and brad nailed the base shoe after figuring out the miters.
I left the corners long and just used a jig saw to cut them off:
Nice profile after flipping it over again:
Here it is dropped in place to see how it fits:
Then I used the random orbital sander with a 220 grit to blend the two edges:
After doing both stairs, I decided to move on to one of the big boys. The front step of the stage. I set it up and marked lines where I would be using the Kreg Jig.
Then started drilling:
Glued and screwed together:
Does anyone know if these 1" kreg screws will make this piece solid enough to actually pick up and flip over onto the stage? I'm a little nervous. So my theory is to run a board across the three pieces and screw into the bottom side helping to unify the entire piece. Otherwise, I may need to call a few friends over for some help.
I also started attaching the base shoe on the under side.
Clamps were helpful in getting the base shoe nicely aligned before brad nailing generously.
I cut the under sides at a 30 degree angle to help hide the joints.
Voila. Now I think it's time to do some clean up. You know it's bad when you actually have to start vacuuming the walls: